Revision: 9.8 Date: 12/03/20
RV-12 MAINTENANCE MANUAL
Aircraft Serial Number: ______Rev: 9.8 12/03/20 REVISION SUMMARY
CHAPTER REVISION DATE COVER PAGE 9.8 12/03/20 ii 9.8 12/03/20 iii 7 09/29/19 iv-x 9 12/03/20 1 9.5 12/13/19 2 1 04/16/10 3 6 09/29/19 4 3 12/18/18 5 6 12/18/18 6 4 07/16/16 7 2 04/03/14 8 5 12/18/18 9 7 12/13/19 10 1 04/16/10 11 7 10/30/20 12 6 09/08/20 13 5 04/03/14 14 4 12/03/20 15 1 04/16/10 16 1 04/16/10 17 4 12/18/18 18 10 09/08/20 19 3 07/16/16 20 4 12/18/18
ii Rev: 7 9/29/19
OWNER/OPERATOR RESPONSIBILITIES
For continued airworthiness of an RV-12 aircraft, the owner/operator must comply with the following requirements as dictated in ASTM F 2295 Section 5.
❑ Each owner/operator of an RV-12 shall read and comply with the maintenance manual and continued airworthiness information and instructions provided by Van's Aircraft Inc.
❑ Each owner/operator of an RV-12 shall provide Van's Aircraft Inc. with up to date contact information so that Van's Aircraft may send the owner/operator supplemental notification bulletins.
Van's Aircraft, Inc. 14401 Keil Road, NE Aurora, OR 97002 USA
Phone: 503.678.6545 Fax: 503.678.6560 Website: www.vansaircraft.com email: [email protected]
❑ The owner/operator of an RV-12 shall notify Van's Aircraft Inc. of any safety of flight issue or significant service difficulty upon discovery using the Feedback Form provided in the Maintenance Manual.
❑ The owner/operator of an RV-12 shall comply with all Van's Aircraft Inc. issued notices of corrective action and comply with all applicable aviation authority regulations in regard to maintaining the airworthiness of the LSA. Notices of corrective action are published on the Van’s Aircraft web site RV-12 Service Information Page. Or go to http://www.vansaircraft.com/public/service-rv12.htm
❑ An owner of an RV-12 shall ensure that any needed corrective action be completed as specified in a notice, or by the next scheduled annual inspection.
❑ Should an owner/operator not comply with any mandatory service requirement the RV-12 shall be considered not in compliance with applicable ASTM standards and may be subject to regulatory action by the presiding aviation authority.
❑ The owner/operator may submit written comments and questions regarding any mandatory Notice to the organization who issued the Notice.
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iv Rev: 9 12/03/20 TABLE OF CONTENTS
CHAPTER 1- GENERAL
INTRODUCTION ...... 1-1 Purpose ...... 1-1 Summary ...... 1-1 Scope ...... 1-2 Replacement Parts ...... 1-3 Method ...... 1-3 APPLICABLE THROUGHOUT ...... 1-4 General Safety ...... 1-4 Safety of Flight Reporting Procedure ...... 1-5 Helpful Terminology ...... 1-5 Abbreviations ...... 1-6 Units ...... 1-7 TOOLS AND EXPENDABLES ...... 1-8 ENGINE ...... 1-12 LUBRICATIONS AND CAPACITIES ...... 1-13 Engine Oil ...... 1-13 Brake Fluid ...... 1-13 Engine Coolant ...... 1-14 Fuel ...... 1-14 Tire Pressures ...... 1-14 Torque Values ...... 1-15 GENERAL PROCEDURES ...... 1-16 Lifting & Supporting the fuselage...... 1-16 WEIGHT AND BALANCE ...... 1-18 EQUIPMENT LIST ...... 1-21
CHAPTER 2- SERVICE SCHEDULE ...... 2-1
OVERVIEW ...... 2-1
CHAPTER 3- INSPECTION ...... 3-1
OVERVIEW ...... 3-1 INSPECTION DESCRIPTION ...... 3-3 Pre-inspection / Post-inspection ...... 3-3 Cockpit ...... 3-5 Radio ...... 3-7 Optional Equipment ...... 3-7 Emergency Locator Transmitter ...... 3-7 Propeller ...... 3-7
v Rev: 9 12/03/20 Engine ...... 3-8 Firewall Forward ...... 3-8 Fuselage ...... 3-10 Landing Gear ...... 3-11 Wing / Center Section/AOA ...... 3-12 Rear Spar Doubler ...... 3-13 Empennage ...... 3-14 Angle-Of-Attack System ...... 3-17 Paperwork ...... 3-17
CHAPTER 4 - STRUCTURAL REPAIRS ...... 4-1
OVERVIEW ...... 4-1 MINIMUM CERTIFICATION ...... 4-2
CHAPTER 5 - STRUCTURES ...... 5-1
OVERVIEW ...... 5-2 FUSELAGE ...... 5-2 WING AND FLAPERON ...... 5-4 EMPENNAGE ...... 5-6 LANDING GEAR ...... 5-8 FAIRINGS - WHEEL AND GEAR LEG ...... 5-10 SERVICE ...... 5-12
CHAPTER 6 - FLIGHT CONTROLS ...... 6-1
OVERVIEW ...... 6-2 SERVICE ...... 6-3
CHAPTER 7 - BRAKE SYSTEM ...... 7-1
OVERVIEW ...... 7-2 SERVICE ...... 7-2
CHAPTER 8 - ELECTRICAL SYSTEM ...... 8-1
OVERVIEW ...... 8-2 SERVICE ...... 8-4
CHAPTER 9 - INSTRUMENTS & AVIONICS ...... 9-1
OVERVIEW ...... 9-2 PITOT & STATIC ...... 9-3 SERVICE ...... 9-4
vi Rev: 9 12/03/20 CHAPTER 10 - UTILITY SYSTEMS ...... 10-1
OVERVIEW ...... 10-2 HEAT ...... 10-2 VENTILATION ...... 10-3 SERVICE ...... 10-4
CHAPTER 11 - PROPELLER ...... 11-1
OVERVIEW ...... 11-2 SERVICE ...... 11-2 Prop & Hub ...... 11-3
CHAPTER 12 - FIREWALL FORWARD ...... 12-1
OVERVIEW ...... 12-2 Engine ...... 12-3 SERVICE ...... 12-3
CHAPTER 13 - FUEL SYSTEM ...... 13-1
OVERVIEW ...... 13-2 Fuel System Schematic ...... 13-3 SERVICE ...... 13-3
CHAPTER 14 - EXHAUST SYSTEM ...... 14-1
OVERVIEW ...... 14-2 SERVICE ...... 14-3
CHAPTER 15 - PAINTING AND COATINGS ...... 15-1
OVERVIEW ...... 15-2 SERVICE ...... 15-3
CHAPTER 16 - TROUBLESHOOTING ...... 16-1
CHAPTER 17 - FEEDBACK & REPLACEMENT PARTS ...... 17-1
REPORTING METHODS ...... 17-1 REPLACEMENT PARTS ...... 17-2 SUBSTITUTE PARTS ...... 17-3
CHAPTER 18 - SUPPLEMENT ...... 18-1
SERVICE SCHEDULE...... 18-3 INSPECTION CHECKLIST ...... 18-7 3-VIEW ...... 18-25 FEEDBACK FORM ...... 18-27
vii Rev: 9 12/03/20 CHAPTER 19 - GLOSSARY ...... 19-1
CHAPTER 20 - INDEX ...... 20-1
NOTE: Pages 1-21 and 1-22 correspond to a particular EFIS installation. Please remove all pages that do not correspond to your EFIS. Specific EFIS type is noted next to the page number.
APPENDIX ‘A’ - KIT ASSEMBLY INSTRUCTIONS (KAI) (NOT PART OF, BUT AN APPENDIX TO THIS MANUAL)
Addendum Documents list (Notification, Service Bulletin, etc.)
DOCUMENT NAME DATE ADDED
viii Rev: 9 12/03/20
TABLE OF ILLUSTRATIONS Figure 1: Tools ...... 1-9 Figure 2: Oil Viscosity ...... 1-13 Figure 3: Lifting and supporting ...... 1-17 Figure 4: Remove for inspection ...... 3-4 Figure 5: Control Stops ...... 3-6 Figure 6: Rivet Inspection ...... 3-10 Figure 7: Wing Retention Pin Bushing ...... 3-13 Figure 7.1: Inspect Rear Spar Doubler ...... 3-14 Figure 8: Rudder Stop ...... 3-15 Figure 9: Fuselage ...... 5-3 Figure 10: Wing and Flaperon ...... 5-4 Figure 11: Empennage ...... 5-6 Figure 12: Landing Gear ...... 5-8 Figure 13: Nose Wheel and Gear Leg Fairings ...... 5-10 Figure 14: Main Wheel Fairings ...... 5-11 Figure 15: Flaperon hinge ...... 5-18 Figure 16: Extracting the DW4K2X bearing ...... 5-20 Figure 16.1: Rear Spar Doubler Replacement ...... 5-24 Figure 17: Locking clip removal ...... 6-4 Figure 18: Tensioner barrel removal ...... 6-4 Figure 19: Torque tube lubrication ...... 7-4 Figure 20: Optional Wing Tip Lighting ...... 8-3 Figure 21: Fuse panel ...... 8-6 Figure 22: Trim/Servo assembly removal ...... 8-8 Figure 23: Pitch-trim servo removal...... 8-8 Figure 24: Stall warning ground ...... 8-10 Figure 25: Snap Bushing ...... 8-13 Figure 26: Rotax 912ULS ...... 12-3 Figure 27: Carburetor Overview ...... 12-8 Figure 28: Mixture Screw ...... 12-9 Figure 29: Throttle Handle Idle Position ...... 12-10 Figure 30: Vacuum Gauge ...... 12-11 Figure 31: Fuel Pressure Hose Flush ...... 13-9
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x Rev. 9.5
CHAPTER 1 - GENERAL
INTRODUCTION
PURPOSE The purpose of this manual is to provide guidance to RV-12 owners, pilots, mechanics, regulatory officials, and aircraft/component manufacturers that are certified to perform maintenance, repairs, and alterations on the light sport aircraft covered in this manual.
SUMMARY This manual contains maintenance instructions for the RV-12 light sport aircraft. The RV-12 is a single engine, fixed tricycle gear, full-cantilever monoplane. The two- seat cockpit is enclosed with a tip-up windscreen/canopy. The occupants sit side-by- side, aft of the engine and forward of the wing spar. Both of the wings are quick removable. The flaperons remain with the wings and self-connect to the control linkage when the wings are installed. The empennage consists of a vertical stabilizer, rudder and stabilator with anti-servo/trim tab. The airframe is a semi-monocoque aluminum structure, with some steel and fiberglass parts. Fiberglass composite parts are used to finish some non-structural portions of the aircraft. The pilot and passenger board the aircraft from either side using the boarding step and a reinforced area near the leading edge of the wing. The pilot is seated on the left side (from within the cockpit) of the aircraft. A combination Electronic Flight Information System (EFIS) and Engine monitoring System (EMS) with graphical user interface is used to monitor and report flight and engine performance information to the pilot. The Rotax 912ULS 100 hp four cylinder engine is enclosed in a fiberglass composite cowling at the front of the aircraft. Engine power is transferred via an integral gearbox to the Sensenich composite propeller. The pilot and the passenger both have full flight and ground controls. Pitch and roll is controlled from either control stick. The control sticks are linked by push/pull rods and torque tubes to the flaperons, and linked by cables to a stabilator. The flap lever controls the flap function of the flaperons. Yaw is controlled using rudder pedals linked by cables to a traditional rudder that is hinged to a fixed vertical stabilizer. The rudder pedals have integrated left and right foot pedals that are used to independently control the wheel brake on the corresponding side.
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SCOPE
• NOTE: This maintenance manual is intended to be used in conjunction with the RV-12 Kit Assembly Instructions (KAI) when completing maintenance or repair processes.
All of the service and maintenance requirements that are unique to the RV-12 S- LSA are included in this manual. The general service and maintenance duties that are common to standard aircraft still apply to the RV-12 regardless of the inclusion of those requirements in this manual. All inspection and maintenance and all maintenance log entries must be made in accordance with 14 CFR / FAR’s. The manufacturers of third party components provide manuals that include complete service and maintenance requirements that are specific to these components. The current service and maintenance manuals from any third party manufacturer, such as; engine, propeller, avionics, etc. always take precedence over the related content in this manual. There are references to third party documentation in this manual, as well as some supplementary information which is for convenience only. It is recommended to refer directly to the manufacturer’s service manuals for complete service information that is unique to applicable components. The manufacturers that provide operating and/or maintenance manuals to use in conjunction with this manual are as follows: Rotax – engine Sensenich – propeller Matco – wheels and brakes Dynon – EFIS / EMS Garmin – EFIS / EMS, GPS and Nav/comm TCW – Backup Battery FlightCom – intercom ACK – ELT Artex – ELT Odyssey – battery Van’s Aircraft − RV-12 Kit Assembly Instructions (KAI).
The service and inspection portions of this manual indicate the minimum certification requirements for a person doing maintenance or repairs on the RV-12. Certification requirements for service and maintenance may vary around the world. It is essential to determine the correct and legal maintenance and certification requirements applicable to the area that the airplane is registered. The documents necessary to determine these requirements for S-LSA in the United States are as follows: RV-12 Maintenance Manual RV-12 Kit Assembly Instructions Federal Aviation Regulations for Light Sport Aircraft Maintenance Technicians Aircraft Inspection, Repair, and Alterations, AC 43.13.
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REPLACEMENT PARTS The RV-12 KAI is the primary reference for replacement part information. Section Four in the KAI is a directory of all part numbers with reference information of where to find it within the main KAI manual. The documentation produced by third party parts manufacturers (listed above) should be used as the primary reference for part information for those components.
METHOD The pages throughout this maintenance manual are numbered at the bottom with the chapter number followed by a dash and the page number of the applicable chapter. There are many cross-references in this manual. Cross-references within this manual are made using the page numbers, unless otherwise specified. Following is an example of a typical cross-reference to additional information within this manual. Example: When there is additional information that is related to this sentence the cross-reference to that page will be in parenthesis following the period. (1-2) Chapter 1 will introduce general information that is helpful for using this manual. General information includes manual introduction, general safety information, notification methods, abbreviations, collective tool list, list of expendables, lubrication and capacities and general procedures. Chapter 2 introduces the service schedule checklist. Chapter 3 provides an explanation of the annual/100 hour inspection checklist including illustrations that clarify some checkpoints of the aircraft. Read Chapter 1–3 prior to performing the inspection, and use it as a reference during the inspection. Chapter 4 and following begin with an illustration of the subject discussed, an ‘Overview’ of the chapter content and a list of ‘Components’. The 'Service' section, where applicable, begins with a table of ‘Supplies’, which includes; ‘Tools’, ‘Expendable’ and ‘Replaceable’ parts. The service section provides instructions for ‘General’ removal, replacement and installation that are acceptable for the owner or operator to perform. The service section also includes instructions for ‘Service Schedule Procedures’ which correspond to the items on the 'Service Schedule Checklist'. Each service section task includes a table that summarizes the properties of the task. The task summary table lists the Tools, Expendable, and replaceable items that are task specific. Only tools specific to the immediate task will be listed. In cases that another task must be done to complete the immediate task, the tools needed for the other task will be given in the instructions that correspond to that task. Some recommended tools will require other tools to be effective; for example: sockets will require a ratchet; drill bits will require a drill. Unless otherwise specified the driving tool is implied rather than listed. The table also includes the ‘Service Rating’ applicable to the task, the ‘Minimum Certification’ required to perform the task legally, and ‘Additional References’ that may be helpful or necessary to complete the task. Each hardware item to be removed in the service instructions will be followed by the quantity (if greater than one) in parenthesis. For example, an instruction step that requires the removal of one
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Rev. 9.5 bolt, six washers and two nuts will appear as follows: 1. Remove the bolt, washers (6), and nuts (2). Chapter 16 offers direction for solving potential problems that may puzzle the owner of any aircraft. Chapter 17 provides instructions for reporting the discovery of anomalies that could compromise the airworthiness of the aircraft. Chapter 18 includes the inspection checklist, service schedule checklist and other helpful documents.
APPLICABLE THROUGHOUT
GENERAL SAFETY Safety must be considered the first priority when performing maintenance or service on an aircraft or part. The content in this manual is only for use in a safe work environment with all necessary safety equipment readily available and in use when applicable. Maintenance or repair classified in this manual as owner and SPC and in 14 CFR, FAR 43 Appendix 'A' can be done by an RV-12 owner or operator that possesses a Sport Pilot certificate or higher. An LSA repairman certificate with a maintenance rating or an FAA issued A&P certificate are the minimum level of certification to perform line maintenance or repairs and the annual condition inspection on an RV-12. Prior to performing maintenance or repair always disconnect the negative (-) battery cable from the battery. The strength of an airframe designed using semi-monocoque construction relies on both the skins and the skeleton for complete structural strength. If a skin has been damaged, typically the underlying structure has also been damaged. Carefully inspect any damage to assess the extent of the damage. If the damage is localized to just outer skins, they can be removed and replaced. If inspection indicates that the substructure is also damaged the aircraft manufacturer must be consulted for further assessment. Every time hardware is removed it must be checked for signs of wear or fatigue. Inspect the head, shank, and threads of bolts, and the edges and threads of nuts. Locking hardware may only be used for one term of service. Safety wire, cotter pins, lock washers and similar hardware are only reliable after one term of service. It is permissible to reuse nylock and all steel style self-locking nuts if it is determined that the self-locking feature has not been degraded. Always replace questionable hardware. Operation in Extreme Conditions: Exposure to extreme climatic conditions, including dust, salt, debris, bugs, will warrant frequent inspections of air filters, coolant radiator, and oil cooler as defined in the Rotax maintenance manual. Frequent exposure to extreme conditions or altitudes demands adjustment of the carburetor and cooling system. Contact an authorized Rotax distributor for consultation.
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SAFETY OF FLIGHT REPORTING PROCEDURE
To maintain the highest level of safety and as dictated in ASTM F 2295 Section 5, the FAA requires, and Van’s Aircraft Inc. requests notification of any safety of flight issue, or service or maintenance difficulties that could compromises the airworthiness of the RV-12 aircraft. A feedback form is provided in the Supplement section of this manual. Refer to Chapter 17 for a description of a valuable report and the different reporting methods available.
HELPFUL TERMINOLOGY
▲ WARNING: INDICATES AN ACTION NECESSARY TO PREVENT INJURY OR DEATH.
■ CAUTION: INDICATES AN ACTION NECESSARY TO PREVENT DAMAGE TO PARTS OR PROPERTY.
● NOTE: PROVIDES VALUABLE ADDITIONAL INFORMATION.
The Glossary provides definitions to many of the terms used throughout this manual.
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ABBREVIATIONS A&P* Airframe and Power-plant Kph Kilometers per hour Mechanic AKI Anti-knock index (octane rating) Kts Knots API American Petroleum Institute lb U.S. pound AST* Anti-servo/trim tab LL Low-Lead AVGAS Aviation Gasoline LSA Light Sport Aircraft C Celsius LSA-RM* Light Sport Aircraft – Repairman Maintenance rating CG Center of Gravity ltr Liter CHT Cylinder Head Temperature m meter cm Centimeter Max Maximum CST* Category specific training mb millibar EFIS* Electronic Flight Information mi Statute mile System EGT Exhaust Gas Temperature Min Minimum ELT* Emergency Locating Transmitter ml Milliliters EMS Engine Monitoring System mm Millimeter F Fahrenheit mph miles per hour FAA United States Federal Aviation naut mi Nautical miles Administration FAR’s Federal Aviation Regulations Nm Newton meters fl. oz. fluid ounce (U.S.) OAT Outside Air Temperature ft Feet oz Ounce ft/lbs Foot-Pounds POH* Pilot Operating Handbook FWD Forward psi Pounds per Square Inch gal Gallon pt Pint (U.S.) GPS* Global Positioning System RON Research Octane Test HP Horse Power RPM Revolutions Per Minute ID Inner Diameter S-LSA* Special Light Sport Aircraft in Inch (depending on context) S/N Serial Number in² Square inches SAE Society of Automotive Engineers in/lb Inch-Pound SPC* Sport Pilot Certified KAI* Kit Assembly Instructions TT Total Time kg kilogram VDC Voltage, Direct Current kPa Kilopascal * -- See glossary for definition
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UNITS: Speed: 1 mph = 1.64 kph = 0.869 kts Distances:
1 in = 2.54 cm 1 ft = 12 in = 0.305 m 1 mi = 5,280 ft = 1.61 km 1 naut mi = 1.15 mi = 1.85 km Mass: 1 oz = 28.3 grams 1 lb = 16 oz = 0.454 kg Pressure: 1 psi = 6.895 kPa 1 mb = 0.1 kPa Volume: 1.8 cubic in = 1 fl. oz = 29.57 ml 1 quart = 2 pints = 32 fl. oz 1 gal = 8 pints = 3.79 ltr Torque: = 1 in/lb = 0.113 Nm 1 ft/lb = 12 in/lb = 1.356 Nm Temperature: (F-32)/1.8 = (1.8 x C)+32
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TOOLS AND EXPENDABLES There are many aircraft tool suppliers available. An Internet search can be conducted to determine which supplier can provide the necessary tools ● NOTE: THIS TOOL LIST DOES NOT INCLUDE ALL OF THE TOOLS SUGGESTED FOR THE INSPECTION PROCEDURES.
TOOLS
Combination Allen wrenches: Wooden dowels 1/2 - 1 inch dia. wrenches: ▪ 3/16 and 1 1/2 - 1 3/4 in. dia. ▪ 1/4 ▪ 1/4 Oil Filter wrench ▪ 5/16 ▪ 5/16 Oil Filter cutter and mallet ▪ 11/32 ▪ 4mm Two 25 in. padded stands ▪ 3/8 ▪ 5mm each rated to support a ▪ 7/16 (2) ▪ 6mm minimum of 500 pounds ▪ 1/2 ▪ 8mm Container (various sizes, ▪ 9/16 Torque wrench suitable for petroleum) ▪ 11/16 (in/lbs & ft/lbs) 24-inch length of 1/2-inch I.D. fuel ▪ 1 1/2 5/8 or 16 mm hose Ratchet spark plug socket Scouring pad or equivalent Sockets: Screwdrivers: Sandpaper (various grades) ▪ 5/16 ▪ #2 Phillips Spark plug gap tool (wire type) ▪ 11/32 ▪ #3 Phillips Compression tester ▪ 3/8 ▪ 3/16 Flat Blade Magnifying Glass ▪ 7/16 Power-drill Small square ▪ 1/2 #30 drill bit Tire air pressure gauge ▪ 9/16 Blind rivet tool Needle nose pliers ▪ 3/4 Straight edge 5-inch “C” clamp ▪ 1 1/2 Razor knife Terminal crimping tool ▪ 10 mm Flashlight Locking (vice grip style) pliers ▪ 11 mm Step ladder 2 1/2 x 3/16 bolt, washer, nut ▪ 13 mm Wire cutters Vacuum gauge set Battery charger Portable weight scale (tension type) Multi-meter Fire extinguisher Syringes Pump style oil can with hose Safety wire twisting pliers
● NOTE: TOOLS DIFFER IN SIZE AND CONFIGURATION. THE FOLLOWING ILLUSTRATIONS ARE ONLY EXAMPLES OF WHAT A TOOL MAY LOOK LIKE.
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Combination Wrenches Ratchet Screwdrivers
Allen Wrenches Sockets Gap Gauge
Oil Filter Cutter Heavy Stands Step Ladder
Oil Filter Wrench Battery Charger Multi-meter
Magnifying Glass Square Air Pressure Gauge
Figure 1 1–9
Rev. 9.5
Razor Knife Flashlight Needle-nose Pliers
C-clamp Terminal Crimper Wire Cutter
Locking Pliers Blind Riveter Power-drill
Hardware Dual Vacuum Gauge Tensile Weight Scale
Figure 1
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■ CAUTION: REPLACEMENT PARTS MUST BE OF EQUIVALENT SIZE, TYPE AND RATING AS THE ORIGINAL PARTS FROM THE MANUFACTURER. EXPENDABLE PARTS PART NUMBER Oil filter Rotax 825 701 Copper crush ring (for drain plug) Rotax 250010 Gas-5 O-ring gasket GASKET GAS-345 Tire U-5:00X5 Tire (any aircraft grade 5:00X5, 4 or 6 ply tire is acceptable. Inner tube U 5:00X5-6IT (any aircraft grade 5:00X5-6 inner tube is acceptable) Brake shoe linings M66-106 (or equivalent) Fuses ATO/ATC ¼ “ blade style 1, 2, 3, 5, 7.5, 30 Amp rating. All fuse values of 3 amp and higher are required to have LED “blown fuse” indicators. LUBRICANTS RECOMMENDATION OR EQUIVALENT Engine oil As specified in latest Rotax documentation Spray lubricant LPS2 or Tri-Flow Dry lubricant (candle wax, etc.) TOOL BOELUBE PASTE Wheel bearing grease Aeroshell 22 or equivalent Thread-lube Loctite 567 or equivalent Anti-seize compound, High temp Loctite Anti-Seize or equivalent Hydraulic fluid MIL-H-5606A or MIL- PRF-83282 Air filter oil EA K&N 99-5050 KIT MISCELLANEOUS RECOMMENDATION OR EQUIVALENT Engine coolant 1:1 Water/Ethylene Glycol (refer to Rotax engine documentation) Safety wire WIRE SAFETY .032 Fuel tank sealant MC-236-B1/2 or MC-236-B2 Plexus Cleaner/Polish CA CANOPY CLEANER Cotter pins MS24665-xyz Plastic tie wraps Non-specific Wire terminals Male & Female spade, splice, and ring Blind rivets LP4-3 (unless otherwise specified) Grey touch-up paint PAINT, TOUCHUP PGRAY Cardinal gray #3607-GR-230 Primer Any protective primer suitable for use on aluminum and/or steel as appropriate Decorative touch-up paint From paint process
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ENGINE
● NOTE: THE ENGINE SPECIFICATION INFORMATION IS REFERENCED FROM THE ROTAX 912 SERIES, OPERATOR’S MANUAL, OM REV.4.
SUMMARY Make Rotax 912 ULS Displacement 1352 cc Ignition Ducati Double CDI Carburetor Bing Rated Horsepower 100 Hp @ 5800 RPM
DESCRIPTION The LSA covered by this manual will have a Rotax 912ULS power plant. The power plant is an over-head valve four-stroke, horizontally opposed four-cylinder. The cylinder heads are liquid cooled. The cylinder barrels are air-cooled. Dual constant depression carburetors regulate the air/fuel mixture. The dual breaker-less, capacitor discharge ignition system provides the electrical energy to the spark plugs. For engine maintenance requirements and procedures refer to the Rotax Engine Type 912 Series line maintenance and heavy maintenance manuals.
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LUBRICATION AND CAPACITIES
ENGINE OIL ■ CAUTION: ONLY USE API CLASS 'SG' OR HIGHER. ■ CAUTION: DO NOT USE OILS WITH FRICTION MODIFIER ADDITIVES. ■ CAUTION: DO NOT USE OILS FOR “CONVENTIONAL” AIRCRAFT ENGINES. ■ CAUTION: DO NOT USE OILS DESIGNED FOR DIESEL ENGINES.
Capacity: 3 ltr (3.2 US qts) The type of oil to use will be based on the type of fuel used. Refer to the Rotax operator’s manual to determine which oil type is compatible with the fuel being used. See Figure 2 to determine the viscosity best suited for the use of the aircraft. Figure 2: Oil Viscosity
BRAKE FLUID
▲ WARNING: NEVER USE AUTOMOTIVE BRAKE FLUID.
Use Mil Spec 5606A or MIL-PRF-83282 Brake fluid draining, flushing, and replacing instructions Page 7-5.
CAPACITY: 15.4 fl. oz. (US) (.455 liters)
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ENGINE COOLANT
SUITABLE COOLANTS
COOLANT MIX: 50% ethylene glycol concentrate with anticorrosion additives designed for aluminum without sulfates and phosphates,. 50% distilled or de-mineralized water. See the latest version of the Rotax Operators Manual and SI 912-016 for further information on coolant types and limitations.
CAPACITY: 0.6 gallon (US) (2.3 liters) Fill expansion tank to between the ‘min’ and ‘max’ marks in the overflow bottle.
MINIMUM: Expansion tank 2/3 full + .2 liter (.4 liq pt) in overflow bottle
FUEL
SUITABLE FUEL 91 AKI (premium unleaded automotive) 100 LL Aviation Fuel See the latest version of the Rotax Operators Manual and SI 912-016 to determine other approved fuel types, limitations and maintenance considerations.
CAPACITY: 19.8 US Gallons (75.0 liters)
TIRE PRESSURES
NOSE TIRE - 22 psi (23 psi maximum) MAIN TIRES - 25 psi (28 psi maximum)
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TORQUE VALUES
Torque applied is for the size of the bolt shank not the wrench size. On smaller bolts use a torque wrench calibrated in inch pounds, not foot pounds.
When tightening fasteners with self-locking nuts the chart values must be modified. The friction drag torque must be determined and then added to the standard torque from the table. Due to the friction of the locking device noticeable torque is required just to turn the nut onto the threads and does nothing to actually tighten the parts together and stretch the bolt (clamp load). This is called friction drag (or prevailing) torque. Run the nut down to where it nearly contacts the washer or bearing surface and check the friction drag torque required to turn the nut. (At least one thread should protrude from the nut). Add the friction drag torque to the standard torque. This sum is referred to as the final (or total) torque, which should register on the indicator or setting for a snap-over type torque wrench.
The propeller manufacturer and the engine manufacturer have specific torque requirements for their equipment. Consult the appropriate manual for that information.
ft-lb in-lb N-m Oil Tank Drain Screw 18 220 25 Oil Filter Contact + 3/4 Turn or as Specified Magnetic Plug 18 220 25 Water Pump Drain Screw 8 90 10 Carburetor Socket Screws 11 135 15 Spark Plugs 16mm 15 180 20 Exhaust Nuts 9 106 12
AN Bolt size - Standard nuts Bolt Threads per inch AN310, size AN315,MS20365 Inch pounds Foot Pounds AN3 #10-32 20-25 1.6-2.0 AN4 1/4-20 50-70 4.2-5.8 AN5 5/16-24 (with plain washers) 100-140 8.3-11.6 5/16-24 (with NORD LOCK washers) 220-240 18.3-20 AN6 3/8-24 160-190 13.3-15.8 AN7 7/16-20 450-500 37.5-41.7 AN8 1/2-20 480-690 40-57.5 AN9 9/16-18 800-1000 66.6-83.3 AN10 5/8-18 1100-1500 91.6-125 (Portions of this information has been adapted from AC 43. 13)
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GENERAL PROCEDURES
TIRE REMOVAL WING REMOVAL REFER TO 5-1 CANOPY REMOVAL COWL REMOVAL REFER TO 12-1 OIL LEVEL CHECK FUEL SYSTEM DRAINING REFER TO 13-1 GASCOLATOR SAMPLE
LIFTING & SUPPORTING THE FUSELAGE
▲ WARNING: USE STURDY SUPPORT STANDS THAT ARE EACH CAPABLE OF SUPPORTING AT LEAST 500 POUNDS. ■ CAUTION: AVOID CONTACTING ANTENNA, FAIRINGS OR OTHER ACCESSORIES WHILE PLACING THE SUPPORT STANDS UNDER THE AIRCRAFT. ■ CAUTION: REMOVE OR ATTACH THE WINGS PRIOR TO LIFTING AND SUPPORTING THE AIRCRAFT.
When the aircraft is lifted, whether or not a jack is used, the method of support is the same. Obtain two sturdy, padded stands each capable of supporting at least 500 pounds. The padded contacting surface must be at least 1 1/2 inches wide. Two layers of 3/8 inch carpet are recommended. Both stands need to be about 30 inches long and 25 inches high.
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Rev. 9.5
LIFTING WITH A JACK ■ CAUTION: USE APPROPRIATE JACK LOCATING FIXTURES TO ENSURE A STABLE JACKING SURFACE. ■ CAUTION: INSTALL A JACKPOINT WHEN LIFTING AT THE WING TIE-DOWN LOCATION. 1. Place a jack as necessary to lift at the lower end of the nose gear-leg. 2. Lift the front of the aircraft enough to position a stand along the lateral rivet pattern, centered directly between the boarding steps. 3. Remove the jack. 4. Place the jack as necessary to lift on the tail tie-down. 5. Lift the tail of the aircraft enough to position a stand along the lateral rivet pattern centered directly beneath the rear wing-spar receptacles. 6. Remove the jack. 7. Test stability of the aircraft. Grab the tail tie-down and test for horizontal and vertical stability. Stabilize as necessary.
LIFTING WITHOUT A JACK
Figure 3: Lifting and supporting ● NOTE: STEPS 1 THROUGH 5 CORRESPOND TO THE NUMBERS IN FIGURE 3. 1. Raise the nose of the aircraft by lowering the tail. 2. Place a 25 inch stand along the lateral rivet pattern, centered directly between the boarding steps. 3. Lift the tail of the aircraft. 4. Place another 25 inch stand along the lateral rivet pattern centered directly beneath the rear wing-spar receptacles. 5. Check for horizontal and vertical stability. Stabilize as necessary.
1–17
Rev. 9.5
WEIGHT AND BALANCE It is the pilot’s responsibility to insure that the aircraft is loaded properly and within the weight and balance limitations. The weight and balance of the aircraft are factors that will affect all flight performance, procedures and characteristics of the aircraft. Find the actual licensed empty weight and CG of the aircraft on the Weight and Balance Form. This document is required to remain with the aircraft and must reflect any changes to the empty weight or CG. From that information and the instructions from the POH the pilot can determine the useful load and proper load distribution for the aircraft.
Weight and Balance Procedure 1. Make a copy of the RV-12 Weight & Balance Worksheet. 2. Install both lower and upper cowl. 3. Check that all fairings, access covers/plates etc are fully installed. 4. Place seat cushions in the aircraft, place the POH and fuel sample tube in the mapbox. 5. Check that there are no other items (tools, etc.) left in the cabin or map box.
6. Roll aircraft onto 2 inch (5cm) blocks under main wheels and chock wheels. 7. Level the canopy deck by inflating/deflating nose tire or main tires as appropriate or by increasing or decreasing block thickness. 8. Drop a plumb line off the leading edge of each wing just outboard of main wheel and mark a line on the floor between the two points. 9. Measure distance forward from left main wheel axle to the line on the floor and record on the RV-12 Weight & Balance Worksheet as D1. 10. Measure distance aft from nose wheel axle to line on floor and record on RV-12 Weight & Balance Worksheet as D2. 11. Measure distance forward from right main wheel axle to line on floor and record on RV-12 Weight & Balance Worksheet as D3.
12. Roll aircraft off blocks under main wheels. Place blocks on scale pads for main wheels. Zero scales. 13. Roll aircraft onto scales using ramps. Verify canopy deck is level (adjust tire inflation if/as necessary), close the canopy. 14. Record the left main wheel weight on RV-12 Weight & Balance Worksheet as W1. 15. Record the nose wheel weight on RV-12 Weight & Balance Worksheet as W2. 16. Record the right main wheel weight on RV-12 Weight & Balance Worksheet as W3. 17. On the RV-12 Weight & Balance Worksheet, calculate empty weight, empty moment, and empty arm. 18. Enter values for Empty Weight, Empty Moment, and Empty Arm into the table on “YOUR AIRPLANE” table within RV-12 Pilot Operating Handbook Section 6. 19. Place the RV-12 Weight & Balance Worksheet in the aircraft as it is part of the required documentation. 20. Enter values for Empty Weight, Empty Moment, and Empty Arm onto the Weight and Balance Record page in this section.
1–18
Rev. 9.5
RV-12 WEIGHT & BALANCE WORKSHEET
AIRCRAFT:______(registration) ______(serial number) DATE:______
TABLE 1 LEFT WHEEL NOSE WHEEL RIGHT WHEEL
WEIGHT ______lb ______lb ______lb (W1) (W2) (W3) DISTANCE FROM AXLE CENTER TO ______inches ______inches ______inches LEADING EDGE (D1) (D2) (D3)
TABLE 2 WEIGHT ARM MOMENT
LEFT WHEEL ______lb (70+_____ ) = ______inches ( _____ )*( _____ ) = _____ in-lb (W1) (D1) (A1) (W1) (A1) (M1)
NOSE WHEEL ______lb (70-_____ ) = ______inches ( _____ )*( _____ ) = _____ in-lb (W2) (D2) (A2) (W2) (A2) (M2)
RIGHT WHEEL ______lb (70+_____ ) = ______inches ( _____ )*( _____ ) = _____ in-lb (W3) (D3) (A3) (W3) (A3) (M3)
EMPTY WEIGHT = ______lb EMPTY ARM = ______inches (W1 + W2 + W3) (Empty Moment / Empty Weight)
EMPTY MOMENT = ______in-lb (M1 + M2 + M3)
Aircraft measured, weighed, and worksheet filled-out by: ______Printed Name/Title
______Signature
1–19
Rev. 9.5
WEIGHT AND BALANCE RECORD
As of this date: ___/___/___ the following values represent current Weight and Balance Calculations.
Revised Empty Weight: ______lb Revised Empty Moment: ______in-lb Revised Empty Arm: ______in
Signed: ______
As of this date: ___/___/___ the following values represent current Weight and Balance calculations resulting from the installation of the ______.
Revised Empty Weight: ______lb Revised Empty Moment: ______in-lb Revised Empty Arm: ______in
Signed: ______
As of this date: ___/___/___ the following values represent current Weight and Balance calculations resulting from the installation of the ______.
Revised Empty Weight: ______lb Revised Empty Moment: ______in-lb Revised Empty Arm: ______in
Signed: ______
As of this date: ___/___/___ the following values represent current Weight and Balance calculations resulting from the installation of the ______.
Revised Empty Weight: ______lb Revised Empty Moment: ______in-lb Revised Empty Arm: ______in
Signed: ______
1–20
Rev. 9.5
INSTALLED EQUIPMENT LIST
ITEM WEIGHT ARM MOMENT
Lbs. In. INSTALLED In-lbs. DYNON 56.62 D-180 GARMIN 55.30 GTX 327 GTX 327 TRAY 53.71 GARMIN 53.86 GTX 328 GTX 328 TRAY 53.88 GARMIN 53.76 SL-40 SL-40 TRAY 47.69 GARMIN X95/6 58.08 FLIGHTCOMFC 56.48 403 ARTEX 96.18 ME-406 DYNON 147.73 EDC-10A BATTERY 43.56
TOTAL ------
1-21 D-180
Rev. 9.5
THIS PAGE INTENTIONALLY LEFT BLANK
1-22
Rev. 9.5
INSTALLED EQUIPMENT LIST
ITEM WEIGHT ARM MOMENT
Lbs. In. INSTALLED In-lbs. DYNON 3.35 58.43 SV-HDX 1100 DYNON (DUAL) 3.35 58.43 SV-HDX 1100 DYNON .63 47.12 SV-EMS-220 DYNON .77 47.66 SV-XPNDR-261 DYNON .8 54.58 SV-BAT-320 DYNON .5 141.73 SV-ADAHRS-200 DYNON .44 43.13 SV-GPS-250 DYNON .44 43.13 SV-GPS-2020 GARMIN 2.37 54.13 GTR 200 ACK 406 1.18 96.18 BATTERY 15.4 43.56 ODYSSEY PC-680 DYNON .3 52.38 SV-ADSB-472 DYNON SV AP .3 57.78 PANEL DYNON SV KNOB .4 57.78 PANEL TOTAL ------
SKYVIEW 1-21
Rev. 9.5
INSTALLED EQUIPMENT LIST
ITEM WEIGHT ARM MOMENT
Lbs. In. INSTALLED In-lbs. DYNON AP SERVO 2 124.80 PITCH DYNON AP SERVO 2 78.64 ROLL
TOTAL ------
SKYVIEW
1-22
Rev. 9.5
INSTALLED EQUIPMENT LIST
ITEM WEIGHT ARM MOMENT
Lbs. In. INSTALLED In-lbs. GARMIN 57.90 GDU 460 GARMIN 57.90 GDU 465 GARMIN 57.57 GMC 305/307 GARMIN 47.12 GEA 24 GARMIN 50.93 GTX 23ES GARMIN 141.73 GMU 22 TCW 50.73 IBBS-12V-3AH GARMIN 118.76 GSU 25 GARMIN 43.13 GA 26C GARMIN 43.13 GA 26XM GARMIN 54.13 GTR 200 ACK 406 96.18 BATTERY 43.56 GARMIN 43.00 GA 36 OR GA 37 GARMIN 47.57 GPS 20A GARMIN
GDL 39R GARMIN AUTOPILOT SERVOS TOTAL ------
1-21 G3X
Rev. 9.5
INSTALLED EQUIPMENT LIST
ITEM WEIGHT ARM MOMENT
Lbs. In. INSTALLED In-lbs. GARMIN
GTR225 PS ENGINEERING
PM3000-RV
TOTAL ------
G3X 1-22
Rev. 1
CHAPTER 2 - SERVICE SCHEDULE
OVERVIEW Adherence to the service (or preventative maintenance) schedule is essential for maintaining airworthiness and maximizing aircraft longevity. There are specific requirements for who can perform preventative maintenance, line maintenance, or annual condition inspections on a LSA.
At least one of the following qualifications is necessary to perform preventative maintenance on an S-LSA RV-12: The owner or operator provided they are Sport Pilot certified or better. A person certified as “Repairman (light-sport aircraft)-Maintenance rating” An FAA certificated A&P mechanic.
At least one of the following qualifications is necessary to perform line maintenance on an S-LSA RV-12: A person certified as “Repairman (light-sport aircraft)-Maintenance rating” An FAA certificated A&P mechanic.
All Inspection and maintenance practices and all inspection and maintenance log entries must be made in accordance with pertinent FARs and the manufacturers' specified requirements.
● NOTE: FOR THE SERVICE SCHEDULE CHECKLIST SEE SUPPLEMENT PAGE 18-3.
2-1
Rev. 1
The service schedule checklist serves as an index of the 'service procedures' section of each applicable chapter. The 'service procedure' section includes the recommended tools to complete each task. Applicable hardware will be stated using the most general terms. Refer to the original KAI for the specific hardware size, location, and configuration. Manufacturers of third party components determine service procedures for those components. The manual provided by the manufacturer for that component will provide service procedures. All component manuals are included with the aircraft at the time of purchase. The ‘What’ column provides the name of the part or components to which the action applies. The ‘Action’ column will indicate what is necessary; replace, lubricate, clean, charge, etc. The ‘When’ column specifies the amount of time or use that may elapse before action is necessary. The ‘How’ column will direct you to the chapter or manual that includes the instructions, tools, supplies, and the level of certification required of the person performing the action, for the given action. Write the date of completion in the ‘Service Date’ column. Use the ‘Initial’ column to identify the person that performed the service.
2-2
Rev. 6
CHAPTER 3 - INSPECTION OVERVIEW ...... 3-2 INSPECTION DESCRIPTION ...... 3-3 Tools ...... 3-3 Pre-inspection / Post-inspection ...... 3-3 Cockpit ...... 3-5 Radio ...... 3-7 Communication ...... 3-7 Intercom ...... 3-7 Transponder ...... 3-7 Optional Equipment ...... 3-7 Emergency Locator Transmitter ...... 3-7 Propeller ...... 3-7 Engine ...... 3-8 Firewall Forward ...... 3-8 Fuselage ...... 3-10 Landing Gear ...... 3-11 Wing / Center Section ...... 3-12 Rear Spar Doubler ...... 3-13 Empennage ...... 3-14 Vertical Stabilizer ...... 3-14 Rudder ...... 3-14 Stabilator ...... 3-16 Anti-Servo Tab & Pitch-trim Servo ...... 3-16 Angle-Of-Attack ...... 3-17 Paperwork ...... 3-17
OVERVIEW The condition inspection is performed annually or every 100 hours of operation, depending on the terms of use for the aircraft. The condition inspection is essential for insuring safe operation throughout the aircraft's service life. In order for anyone to perform a condition inspection on an S-LSA category RV-12 aircraft they must possess at least one of the following SPECIFIC CERTIFICATION REQUIREMENTS:
A person certified as “Repairman (light-sport aircraft)-Maintenance” rating FAA certificated A&P technician
● NOTE: FOR THE INSPECTION CHECKLIST SEE SUPPLEMENT PAGE 18-5.
• NOTE: This maintenance manual is intended to be used in conjunction with the RV-12 Kit Assembly Instructions (KAI) when completing maintenance or repair processes.
The inspector will identify any wear, corrosion or damage that would compromise the safe operation of the aircraft. All inspection practices must comply with the current Advisory Circular 43.13-1B regardless of the content of this manual. During the inspection, locations concealed from direct line of sight may be accessible by touch or with use of a mirror. Inaccessible places do not require
3-1
Rev. 6 inspection provided the airframe has been constructed and used within the terms defined by the manufacturer. The Inspection Checklist provided in the Supplement will be a guide for the inspection procedure. The bold print identifies each category of inspection and the general symptoms to check for throughout that category. Each category inspection item identifies specific things to check for with that item. Generally the items on the Inspection Checklist will correspond to the bulleted items in this chapter. It is always important to be generally observant to the condition of the aircraft regardless of what is specified for inspection. During the inspection make note in the space provided or on a separate document of any discrepancies with parts, components or fasteners that require service or replacement. Complete the entire inspection prior to performing service or repairs. This chapter recommends tools that are useful for each inspection category.
3-2
Rev. 6
INSPECTION DESCRIPTION
TOOLS Inspection Mirror Multi-meter Clean rags Compression tester Straight edge (avoid scratches; tape Torque wrench (in/lbs & ft/lbs) along one edge) Tire pressure gauge Small square Jack Screwdrivers: Padded stands ▪ #2 Phillips Step ladder Socket: Flashlight ▪ 3/8 Magnifying Glass Wing Retention Pin Bushing Gauge
PRE-INSPECTION / POST-INSPECTION Perform the preliminary systems check and engine run-up. The Rotax line maintenance manual provides the run-up procedure for the engine. Test all of the engine systems and controls. Test all of the airframe systems and controls. Make note of any abnormalities or dysfunctional components. Record the applicable values in the spaces given on the Inspection Checklist. After the systems check, proceed with the following:
■ CAUTION: ALWAYS SUPPORT THE FLAPERON DURING WING REMOVAL AND STORAGE.
1. Remove the left and right wing. 2. Remove all access covers, inspection plates, fairing and cowling shown in Figure 4.
Tools 3/8 socket #2 Phillips screwdriver Service rating Line Minimum Certification LSA-RM, or A&P
3-3
Rev. 6
Figure 4: Remove for inspection *Ref. # Name *Ref. # Name 1 Left Wing 12 Access Hatch 2 Right Wing 13 Seat Floor Cover 3 Forward Skin 14 Cover Plates (5) 4 Upper Forward Fuselage 15 Baggage Floor Cover Skin 5 Top Cowl 16 Baggage Cover 6 Bottom Cowl 17 Baggage Bulkhead Corrugation 7 Spinner 18 Lower Tailcone Fairing 8 Tunnel Cover 19 Upper Tailcone Fairing 9 Step Floor Cover 20 Fuel Tank Assembly (see chapter 13 for 10 Seat Ramp Cover draining the fuel tank) 11 Fuselage Side Cover (2) * - Not numbered in order of removal 3. Perform visual inspection for and make note of any oil, exhaust, fuel, hydraulic or reother leaks. 4. Thoroughly clean engine, fuselage, cockpit, undercarriage and other areas as needed to allow thorough inspection. 5. Throughout the inspection check for cracks, signs of fatigue, corrosion, wear, deformation, and/or failure. Always check condition and security of all safe- tied fasteners.
3-4
Rev. 6
COCKPIT Tools Magnifying glass Clean rag Flashlight Straight edge Inspection mirror
• Inspect the aft face of the firewall for corrosion, deformation or cracks, especially around fasteners. • Inspect each occupant harness latching mechanism, the condition of the strap material and stitching. • Check the installation, fasteners and condition of each seat back. • Inspect the canopy windscreen and aft window for deterioration or breakage. The canopy latch and latch block must be in good condition and installed correctly. Test the security of the roll bar and check for any sign of fatigue. Check the canopy frame for cracks / security. • Check that the control panel items are marked permanently, clearly, and correctly. • Inspect all switch panel and instrument panel connections for security and condition. • Test all position lights, landing lights and cockpit lights for operation. • Check the condition of in-service fuses and the condition and presence of spare fuses. • Run a rag along the control cables to check for frays or broken strands that will snag the cloth. The stabilator cables must be aligned with the corresponding pulley and free from physical interference. The locking clips on the tensioner barrels must be installed and secure. • Actuate the control stick forward and aft to check the pulley operation. The pulleys must turn smoothly, without lateral play. With the control stick pulled back the trailing edge of the stabilator must be up. • Hold either control stick stationary and gently wiggle each push/pull rod; there must not be free play or loose parts. Check the rod-end jam nuts for proper torque and check the security of the rod-end connection fasteners. • Actuate the control stick left and right. Operation must be smooth from stop to stop. • Operate the flap lever to each detent. At each flap lever detent, check the full motion of the control stick for smooth operation.
3-5
Rev. 6
• Make sure the stabilator contacts its up and down stops before the WD-1210 Control Column contacts its up and down stops. If not, loosen and tighten the stabilator cable tensioner barrels an equal and opposite amount until the travel is full and correct. The control column stops must limit excessive forward and aft pressure. The bellcrank stops must limit the left and right control stick motion. See Figure 5.
Figure 5: Control Stops • Actuate the vent door on each side of the cockpit and confirm a clear passage. Actuate the cabin heat push/pull cable, confirm a clear passage to the cabin (when 'On'), and smooth operation. Confirm that the heat door has a tight seal to the firewall when heat control is in the off position. • Test the full motion of each of the engine control cables for smooth operation and proper operation of the friction (throttle control) or position lock (choke control). • Test the operation of the fuel valve. Check the security of the electric fuel pump and the fuel flow transducer. • Inspect the system lines that run along the center, of the bottom skin. Check all fittings for leaks. The system lines include (from left to right while seated in the cockpit); electrical wire bundle & static line, fuel return, left brake line, right brake line, and fuel supply. There must be snap bushings at each bulkhead and clamps or brackets to hold the lines secure. • Test the operation of the brake pedals. Constant pressure must not cause any of the brake pedals to bottom out. Without pressure, each brake pedal must automatically return to the original position. • The rudder pedals must move opposite and relative to each other with no slack between them. The rudder stops on the lower rudder hinge must limit the rudder and pedal travel.
3-6
Rev. 6
RADIO • Check the connections, external condition, and installation of each component; the main unit, the antenna and the jacks.
COMMUNICATION • Test the operation of the unit per manufacturer specs. (Refer to the Garmin or Dynon installation manual)
INTERCOM • (If Installed) Test the operation of the unit per manufacturer specs. (Refer to the FlightCom manual)
TRANSPONDER • Make sure the transponder is in compliance with FAR 91.403 and log entries current.
OPTIONAL EQUIPMENT • Confirm that optional equipment installed on the aircraft is correct and authorized. Optional equipment is offered and installed on the aircraft by the manufacturer at the time of purchase. Refer to the related manual for special procedures for inspection. (See applicable manual provided with the component)
EMERGENCY LOCATOR TRANSMITTER • The ELT must be inspected in compliance with the FAR Part 91.207 (d) and accompanied by a logbook entry.
PROPELLER (Refer to Sensenich Propeller manual)
▲ WARNING: THE MASTER POWER AND BOTH IGNITION SWITCHES MUST BE SHUT OFF DURING INSPECTION OF THE PROPELLER. SERIOUS INJURY OR DEATH WILL RESULT IF ENGINE IS UNINTENTIONALLY STARTED BY TURNING THE PROPELLER. • Check the spinner cone and back-plate fasteners for wear and security. • Inspect hub and fasteners for cracks and wear. • Check the pitot tube and bushing for wear and condition. • Check hub fastener torque. • Inspect the leading edge of the blades for loose metal. Inspect each entire blade for
3-7
Rev. 6
cracks, missing material, and delamination.
● NOTE: PERFORM THE PROP TRACK TEST WITH THE SPARK PLUGS REMOVED.
• Test prop track by placing a stationary object in contact with the forward or aft face of one of the blade tips. Then rotate the propeller to bring the opposite blade to the same point. An off-track propeller will not come to the same point.
ENGINE (Refer to Rotax manual)
▲ WARNING: THE MASTER POWER AND BOTH IGNITION SWITCHES MUST BE SHUT OFF DURING INSPECTION OF THE ENGINE, UNLESS INSTRUCTED OTHERWISE. SERIOUS INJURY OR DEATH WILL RESULT IF ENGINE IS UNINTENTIONALLY STARTED. ▲ WARNING: ALLOW THE ENGINE AND APPLICABLE COMPONENTS TO COOL BEFORE PERFORMING SERVICE OR INSPECTION. HOT ENGINE COMPONENTS WILL CAUSE SERIOUS BURNS.
• Refer to the Rotax line maintenance manual for proper inspection procedure for engine and components supplied with engine. The Rotax manual will also provide fluid check and change procedure.
FIREWALL FORWARD
▲ WARNING: THE MASTER POWER AND BOTH IGNITION SWITCHES MUST BE SHUT OFF DURING INSPECTION OF THE FIREWALL FORWARD COMPONENTS. SERIOUS INJURY OR DEATH WILL RESULT IF ENGINE IS UNINTENTIONALLY STARTED. ▲ WARNING: ALLOW THE ENGINE AND APPLICABLE COMPONENTS TO COOL BEFORE PERFORMING SERVICE OR INSPECTION. HOT ENGINE COMPONENTS WILL CAUSE SERIOUS BURNS.
Tools Magnifying glass Clean rag Flashlight Compression Inspection mirror tester Multi-meter
• Note any signs of leakage, corrosion, and high temperature. Check for wear to hoses, cables, wiring harnesses, etc. as a result of vibration while in contact with another object.
3-8
Rev. 6
• Check the forward side of the firewall especially around components and fasteners, around the battery, oil tank assembly, heat exchangers, cowl attach locations, engine mount, and nose gear. The firewall must not have any open passages into the cockpit. • Inspect the engine mount for damaged coating, corrosion and signs of fatigue or cracks. Damaged engine mount coating demands closer examination and repair. • Inspect the engine vibration isolators for cracks, deterioration and installation. • Check the engine compartment wiring, including ground wires of the wiring harness. Wire insulation must be secure, intact and flexible; free from cracks, burns, or separation. All wire terminations must be tight. • Check the battery for proper voltage, condition of the case, and that the connections are secure. • Engine cooling shroud must be secure and free of cracks. • Cabin heat cable and connection must be secure and operate smoothly. All ducting must be secure and in good condition. Heat door must close tightly against firewall (when 'Off'). • Check each engine control cable for security and condition along the route to the firewall. The throttle and choke cables must be securely connected to each of the carburetors and in good condition. Throttle and choke cables must operate the carb levers from stop-to-stop. • Inspect the air filters for cleanliness, attachment and condition. • Inspect the heat exchangers for proper attachment, cleanliness and condition. • The flexible lines provided with the engine have a service life defined in the Rotax maintenance manual. Static and other flexible lines must be in good condition, connected and fastened securely. • Check the fuel lines for good condition, secure mounting, routing and connections. Inspect the the screen and bowl of the gascolator for contaminant build-up. Check the O-ring for condition and deterioration. • Check the exhaust system for security. Check for signs of exhaust leaks. • Check exhaust system ball joints for proper anti-seize lubrication. • Inspect the cowling for overall condition; loose paint, material separation, signs of wear. Check the cowl fasteners and hinges for missing eyelets, security. Check cowl shielding for signs of high temperature and proper attachment to cowl. • Check for cotter pins in place in the engine mount attach castle nuts.
3-9
Rev. 6
FUSELAGE Tools Magnifying glass Clean rag Flashlight Straight edge Inspection mirror
Inspect the exterior of the fuselage skins and fasteners. Check the fasteners by sighting along each rivet pattern for any inconsistent rivet profile among properly installed rivets as shown in Figure 6.
Figure 6: Rivet Inspection
• Critical areas are where the firewall attaches to the fuselage, each wing spar mates with the fuselage, the tailcone attaches to the forward fuse, and the empennage components attach to the tailcone. • Visually inspect that both static ports are clear. • Test the condition and security of the left and right boarding steps. • Inspect the condition of the electrical connections that correspond to the wing. The connections must be free of corrosion and any damage. • Inspect the inside diameter of each flaperon torque tube for rust/corrosion and verify that the UHMW plastic spacers are in place in the actuating arms of the flaperon torque tubes.
3-10
Rev. 6
LANDING GEAR
▲WARNING: A LIFTED AIRCRAFT MUST BE SECURELY SUPPORTED BY STATIC STANDS OTHER THAN THE JACKING DEVICE. THE AIRCRAFT MAY NOT MOVE FROM ATTEMPT TO SHAKE HORIZONTALLY OR VERTICALLY. ■CAUTION: ALWAYS USE PADDED STANDS AND ALWAYS DISTRIBUTE THE LOAD ALONG A RIVET PATTERN WITH SEVERAL INTERSECTING RIVET PATTERNS. ●NOTE: REFER TO GENERAL – GENERAL PROCEDURES INDEX FOR INSTRUCTIONS ON LIFTING AND SUPPORTING THE AIRCRAFT.
Tools Magnifying glass Clean rag Flashlight Straight edge Inspection mirror Sawhorses Torque wrench Tensile weight scale
Check all landing gear components; attach locations, and fasteners for cracks and any other signs of fatigue. Throughout the inspection of the landing gear, be observant for signs of hydraulic fluid leakage. • Inspect each landing gear-leg and attach point Check for evidence of black dust at the attach points which is an indicator of movement. • Test the security of each of the landing gear-legs. The landing gear components may not have any free play in any direction. • Check that all attach hardware is at proper torque. Remember to account for the prevailing torque of the nut. If a torque wrench is used on the head of the bolt also account for the torque to overcome the friction to turn the bolt shank within the assembly. • Check the main U-1220 gear legs for corrosion or bubbled paint that may lead to corrosion. • Test the security of the brake lines and inspect for signs of wear. • Grab and shake the wheels and tires to check for bearing looseness. • Check for smooth, low resistance rotation of each wheel. • Check for excessive play in both brake calipers. • Check the brake shoe linings, brake disc and wheel assembly per Matco manufacturer specifications. • Rotate the nose fork about the gear-leg. Check for lubrication. Check the break-out force per KAI.
3-11
Rev. 6
• Use a straight edge to check that the unloaded gear-leg is straight, between the factory bends. • Inspect the condition of fasteners and cotter pins, and the condition of attach locations at the nose fork pivot point and the three wheel axles. • Inspect the tires for cracks, wear, and tire pressure. Valve and valve stem in good condition, and capped. • Check the nose gear-leg coating, welds, and brackets for cracks and signs of fatigue. • Check nose fork pivot point for lubrication. • Check the nose fork, nut and cotter pin for condition and signs of fatigue.
WING / CENTER SECTION Tools Magnifying glass Clean rag Flashlight Straight edge Inspection mirror Multi-meter Wing retention pin bushing gauge
• Inspect the wing skins and fasteners for signs of damage or deformation. Check the fasteners by sighting down each rivet pattern for any inconsistent rivet profile among properly installed rivets. Any damage observed on the wing skins demands thorough inspection of the understructure of the damaged wing. • Use a flashlight and an inspection mirror to inspect spars, ribs and attach angles on the interior of each wing. Especially the inboard-most ribs and ribs at the flaperon hinge attach points. The aft outboard portion of the wings can be viewed through the lightening holes in the outboard portion of the rear spar. • Inspect the main spar, rear spar and stub spar for corrosion, deformation, signs of wear or fatigue. Inspect the rear spar and stub spar for lubrication at the inboard end. • Inspect the flaperon condition and operation. Inspect the flaperon skins and fasteners for damage or deformation. The flaperon must swing smoothly without free play in any direction. Inspect the flaperon control connection for signs of wear. Check the fasteners in the flaperon hinge brackets on each wing for security. Inspect inner surface of flaperon torque tubes for rust and corrosion. • Inspect the condition of the electrical connections that correspond to the fuselage. The connections must be free of corrosion and damage. • Test the stall warning Vane for freedom of movement. Check the micro-switch for corrosion, condition and security. Check the wing skin for cracks around the stall warning vane penetration. • Test the AOA system plumbing for leaks. See the AOA System Test section below.
3-12
Rev. 6
• Check fuselage pin latching mechanisms for security and proper operation. Test warning circuit by moving each latch independently and verifying warning light. • Inspect each fuselage pin and all wing retention pin bushings for wear or cracks. Inspect the center section area around the bushings for deformation or cracks. Use the Main Spar Bushing Gauge Pin to check the wear of both ends of all of the wing retention pin bushings. Insert the Gauge Pin into the bushing, then rotate the Gauge Pin. The Gauge Pin is a 'go, no-go' device. If the 'no-go surface' contacts the bushing (or mounting surface), the wing retention pin bushing must be replaced. See Figure 7. Figure 7: Wing Retention Pin Bushing • Inspect the center section channel, bulkheads, fasteners and stiffeners for signs of amage or fatigue. Check the center section left and right UHMW retainer block and roller for security and wear. • Check the fuselage pin latching mechanisms for security and proper operation. Test the warning circuit by unlatching each pin individually to verify it causes the switch panel warning light to illuminate.
REAR SPAR DOUBLER • If the W-1207B rear spar doubler has been trimmed too much, the finished airplane may exhibit some play at the rear spar junction. This is usually discovered by hearing a “click” and detecting in/out movement when the wing is installed. Increasing the length of the spar doubler is not possible, so it must be removed and replaced with a different, slightly longer, part. • To determine which part is required, measure the in/out movement of the wing. This will require two people. • Begin by chocking the tires firmly, so the fully assembled airplane rocks and moves as little as possible. • Attach a dial caliper to the inboard wing skin as shown below and adjust it so it just touches the side of the fuselage. (Use a spacer between the caliper and the wing skin, if necessary, to clear the rubber wing root seal). One person can rock the wingtip forward and aft while the other checks the indicator, and measures the total play.
3-13
Rev. 6
• If your aircraft has ES-00076 & ES- 00077 Electrical Connectors (See KAI 31B-08 and 31B-18) and the measurement is less than 0.050 no repair is required. • If your aircraft has tab style VA-262 electrical connectors in UHMW (See KAI 31-02) and the measurement is less than 0.010 no repair is required. • For repair instructions see Section 5. Figure 7.1: Inspect Rear Spar Doubler
EMPENNAGE Tools Magnifying glass Straight edge Flashlight Inspection mirror
VERTICAL STABILIZER • Check the main skin and forward skin for deformation or cracks. • Check the main skin fasteners by sighting along each rivet pattern for any inconsistent rivet profile among similar properly installed rivets. • Check the forward spar and fasteners for cracks, deformation and signs of fatigue. • Inspect the rear spar, spar fasteners, and hinges for cracks, deformation and signs of fatigue, especially the areas surrounding the rudder hinge brackets. • Check the fiberglass fairing for condition and security. • Check for interference or signs of wear from the rudder. • Look through the forward spar lightening holes to inspect the rear spar, ribs, and rib flanges for cracks.
RUDDER • Check the main skin for damage or deformation. • Sight along each rivet pattern for any inconsistent rivet profile among similar properly installed rivets. • Check the spar and hinge brackets for cracks, deformation and signs of fatigue, especially the areas surrounding the hinge brackets.
3-14
Rev. 6
• Check the fiberglass fairing for condition and security. • Check the rudder control horn for coating damage. Inspect for cracks, missing fasteners and deformation. • Check the spar bottom rib surrounding the rudder horn for cracks or deformation. • Inspect the control cable swages, link fasteners and attach area on the control horn for signs of wear or fatigue. • Check the rudder stops on the lower hinge for wear or deformation. • Make sure the rudder swings smoothly and the control horn contacts the rudder stops square and flush as shown in Figure 8.
Incorrect
Correct Incorrect Figure 8: Rudder Stop
3-15
Rev. 6
STABILATOR • Check the main skin for damage or deformation. • Check the main skin fasteners by sighting along each rivet pattern for any inconsistent rivet profile among similar properly installed rivets. • Inspect the Anti-Servo Tab hinges, fasteners, and safety wire for wear and security. • Inspect the spar box for cracks, deformation or signs of fatigue, especially the areas surrounding the control horns, hinge brackets, and counterbalance brackets. • Use an Inspection mirror to inspect the ribs for cracks or deformation. • Inspect the coating on the control horns, counterbalance brackets. • Check the counterbalance arm for straightness and for interior/exterior corrosion, remove bolts if necessary. • Make sure the counterbalance weights are secure and the fasteners are in good condition. • Inspect the hinge brackets, stops, and fasteners for signs of wear and security. • Inspect the control horns and fasteners for wear and security. • Check the control cable fasteners for security or signs of wear. • The stabilator must swing smoothly and be limited only by the hinge stops. Make sure that both hinge brackets on the tailcone contact their corresponding hinge stop on the stabilator squarely and simultaneously.
ANTI-SERVO TAB & PITCH-TRIM SERVO • Check the anti-servo tab skins for damage or deformation. • Check the anti-servo tab fasteners by sighting along each rivet pattern for any inconsistent rivet profile among similar properly installed rivets. • Check the spar and attach hinge for deformation and signs of fatigue. • Inspect the control horns and surrounding area for deformation, cracks, and signs of fatigue. • Check the control horn fasteners for wear and security. • Inspect the pitch-trim servo push rod and link for damage or signs of fatigue. • Inspect the pitch-trim servo, and servo tray for deformation or cracks. • Check the fasteners and bushings that connect the pitch-trim servo tray to the tailcone for security and wear. There should be very little movement in the tab when the stabilator is held fixed. • Check the electrical connections and wire for condition and wear. • Test the operation of the AST by actuating the stabilator through its full range of motion with the trim adjusted to the full nose up and full nose down settings. AST movement must be smooth and relative to the stabilator movement. There must not be any interference with the AST and the pitch-trim servo components at any point of the stabilator travel.
3-16
Rev. 6
ANGLE-OF-ATTACK SYSTEM TEST Tools Syringes - two req'd (35cc or similar) Modeling clay Vacuum hose (or soft plastic tubing)
NOTE: THE AOA SYSTEM PLUMBING MUST PASS THIS LEAK TEST DURING EVERY INSPECTION AND EVERY TIME THE WINGS ARE REMOVED AND INSTALLED.
WHEN PERFORMING ANY AOA, STATIC, OR PITOT SYSTEM PRESSURE TEST ON A DYNON SKYVIEW SYSTEM IT IS REQUIRED TO BE AT SOFTWARE VERSION 15.0.4 (OR GREATER) AND ALL TESTING MUST BE PERFORMED IN THE SETUP MENU > HARDWARE CALIBRATION > ADAHRS CALIBRATION > PITOT/STATIC TEST MODE.
After the AOA system has been properly calibrated in flight, this test is used to test the AOA system plumbing integrity during every inspection and every time the wings are removed and re-installed.
• Using a 35cc syringe push plunger in to 7.5cc, hook-up syringe & vacuum hose to pitot tube, turn-on EFIS, use syringe to slowly, carefully push air into pitot, look for airspeed indication on EFIS, push-in syringe until 130 kt indicates then stop pushing- in. • Using a second syringe push plunger in to 7.5cc. Use modeling clay to hook-up the syringe and vacuum hose to the AOA port. • Pressurize the AOA port. Watch the EFIS AOA indicator. Increasing AOA port pressure will cause the EFIS AOA indicator to move from green to red. Do not apply more pressure than necessary to move the AOA indication into the red zone. Once the AOA indication is in the red zone stop pushing in the syringe. • Move the left wing tip back and forth, as per the REAR SPAR DOUBLER instructions in the WING/CENTER SECTION, while performing the AOA system leak test to verify AOA system integrity. • The maximum allowable AOA system leak rate is less than full AOA indicator scale, from red to green, in one minute. • If the AOA system does not hold test pressure for the required time inspect the modeling clay to wing seal before inspecting other AOA system components. Inspect and repair or replace any faulty AOA system components, as necessary. If faulty components were replaced or repaired re-test the AOA system plumbing integrity. PAPERWORK • Make the appropriate log book entries. • Save the completed checklist in the aircraft file.
3-17
Rev. 6
THIS PAGE INTENTIONALLY LEFT BLANK
3-18
Rev. 3
CHAPTER 4 - STRUCTURAL REPAIRS
OVERVIEW Visible deformation of or damage to any aircraft skin warrants a complete inspection of the underlying parts or structures. If all damaged parts are replaced in accordance with the Kit Assembly Instructions KAI no consultation of the manufacturer is necessary.
Small patch repairs to skins as outlined in AC 43.13 are allowed without consulting the aircraft manufacturer if the total patch area does not exceed 60 square inches. Repair to interior structural parts of the airframe or skin repairs (other than replacement of the entire skin or patches to skins) of more than 60 square inches are not allowed without consulting with the airplane manufacturer and receiving approval of the planned method of repair. Note: Integral stringers formed on the edge of skins are considered interior structure.
4-1
Rev. 3
• NOTE: This maintenance manual is intended to be used in conjunction with the RV-12 Kit Assembly Instructions (KAI) when completing maintenance or repair processes.
• NOTE: For more information regarding riveting, metal working, fiberglass, fluid fittings, priming, painting and more refer to the KAI Chapter 5; Construction Material s, Processes & Useful Information.
• NOTE: Stop drill cracks per AC 43.13. Report any cracks to Van's Aircraft using the feedback form found at the back of this manual.
• NOTE: See Section 17, Substitute Parts, for rivet substitutions that may simplify maintenance and repair.
MINIMUM CERTIFICATION The minimum certification for completing a repair to aircraft skins is an LSA Repairman – Maintenance or an FAA certificated A&P technician. Refer to the KAI to identify individual parts and their corresponding part numbers.
4-2
Rev. 6
CHAPTER 5 - STRUCTURES
OVERVIEW ...... 5-2 Installation ...... 5-14 Main wheel and tire assembly removal ...... 5-15 FUSELAGE ...... 5-2 Installation ...... 5-15 Components ...... 5-3 Nose wheel and tire assembly removal ...... 5-16 WING AND FLAPERON ...... 5-4 Installation ...... 5-16 Main inner tube replacement ...... 5-16 Components ...... 5-5 Nose inner tube replacement ...... 5-17 EMPENNAGE ...... 5-6 Flaperon hinge replacement ...... 5-17 Components ...... 5-7 Rudder hinge replacement ...... 5-18 Stabilator hinge replacement ...... 5-19 LANDING GEAR ...... 5-8 Main gear removal ...... 5-21 Components ...... 5-9 Installation ...... 5-21 NOSE WHEEL & GEAR LEG FAIRINGS .. 5-10 Nose gear removal ...... 5-21 Installation ...... 5-22 Components ...... 5-10 Belt and Harness replacement ...... 5-22 Wheel Fairings ...... 5-11 Canopy latch block replacement ...... 5-23 Optional Components ...... 5-11 Step replacement ...... 5-23 Rear Spar Doubler Replacement ...... 5-23 SERVICE ...... 5-12 Service Schedule Procedures ...... 5-25 Supplies ...... 5-12 Wing attach location lubrication ...... 5-25 Tools ...... 5-12 Fuselage pins ...... 5-25 Expendable ...... 5-12 Stub spar and Rear spar ...... 5-25 Replaceable ...... 5-12 Flaperon control connection lubrication ...... 5-25 General ...... 5-13 Flaperon bearings lubrication ...... 5-26 Wing removal ...... 5-13 AST attach hinge lubrication ...... 5-26 Installation ...... 5-13 Nose wheel bearings replacement ...... 5-26 Wing retention pin bushing replacement...... 5-13 Main wheel bearings lubrication ...... 5-27 In Center Section: ...... 5-13 Nose fork pivot tension and lubrication ...... 5-28 In Wing Spars: ...... 5-14 Tire Assem. Balancing Procedure……….….5-29 Canopy and frame removal ...... 5-14
5-1
Rev. 6
OVERVIEW The RV-12 airframe uses blind (pop style) rivets as the primary fastener. The wings are removable without the need of tools. Screws, bolts and solid rivets are used where necessary.
• NOTE: PRIOR TO PERFORMING STRUCTURAL REPAIRS READ CHAPTER 4 FOR LIMITATIONS.
• NOTE: THIS MAINTENANCE MANUAL IS INTENDED TO BE USED IN CONJUNCTION WITH THE RV-12 KIT ASSEMBLY INSTRUCTIONS (KAI) WHEN COMPLETING MAINTENANCE OR REPAIR PROCESSES.
▲WARNING: BEFORE PERFORMING ANY MAINTENANCE OR REPAIRS TURN THE MASTER SWITCH 'OFF' AND DISCONNECT THE NEGATIVE (-) BATTERY CABLE FROM THE BATTERY.
FUSELAGE The fuselage will be identified as the forward fuselage and the tailcone. The forward fuselage is the baggage bulkhead and all airframe parts forward to, and including, the firewall. The tailcone refers to all of the parts behind the baggage bulkhead, excluding the empennage fairing and empennage components.
5-2
Rev. 6
Figure 9: Fuselage
COMPONENTS Quantity Part or Assembly Name Part Number or Reference 1 Canopy and Frame C-1201 & WD-1219 1 Fuselage Refer to KAI 2 Fuselage Pin WD-1217 4 Wing Retention Pin Bushing W-1206U 1 Latch Block C-1205 2 Occupant Harness System See shaded items below & Refer to KAI 1 Shoulder Harness 1 Lap Belt 1 Crotch Strap 1 Left Step WD-1233-L 1 Right Step WD-1233-R
5-3
Rev. 6
WING AND FLAPERON The wing and flaperon are removable as an assembly from each side of the fuselage. Each wing mates to the fuselage at three points; the stub spar, the main spar and the rear spar. Two fuselage pins secure both main spars to the center section of the fuselage. Electrical and control connections connect automatically during wing attachment. The left wing has a stall warning sender installed. With the wing detached from the fuselage, the flaperon is removable.
Figure 10: Wing and Flaperon
5-4
Rev. 6
COMPONENTS Quantity Part or Assembly Name Part Number or Reference 1 Left Wing See shaded items below & Refer to KAI 2 Wing Retention Pin Bushing W-1206U 1 Stub Spar W-1208B-L / W-1208C-L 1 Rear Spar W-1207A-L / W-1207B 1 Stall Warning See 5-5 1 Right Wing See shaded items below & Refer to KAI 2 Wing Retention Pin Bushing W-1206U 1 Stub Spar W-1208B-R / W-1208C-R 1 Rear Spar W-1207A-R / W-1207B 1 Right flaperon Mirror of Left Flaperon (See below) 1 Left Flaperon See shaded items below & Refer to KAI 2 Flaperon Hinge MD3614M 1 Actuation Bracket A-1207-L 1 Pivot Guide A-1211
5-5
Rev. 6
EMPENNAGE The empennage components include the vertical stabilizer, rudder, anti- servo/trim tab, and stabilator assemblies. The vertical stabilizer front and rear spar attach to the tailcone. Fiberglass fairings finish the top of the vertical stabilizer and rudder. The rudder is attached through hinges on the rear spar of the vertical stabilizer. The stabilator attaches to hinges on the aft bulkhead of the tailcone. The AST attaches to the rear of and operates in sequence with the stabilator. The AST also functions as a trim-tab. Refer to the KAI for empennage component removal and installation.
Figure 11: Empennage
5-6
Rev. 6
COMPONENTS Quantity Part or Assembly Name Part Number or Reference 1 Vertical Stabilizer See shaded items below & Refer to KAI 1 Lower Hinge VS-1210 / VS-1211A / COM-3-5 1 Upper Hinge VS-1210 / VS-1211B / COM-3-5 1 Fwd Skin VS-1204 1 Rudder See shaded items below & Refer to KAI 1 Rudder Horn WD-1205 1 Stabilator See shaded items below & Refer to KAI 2 Hinge Bracket HS-1213A / HS 1213B / HS-1210 1 Anti-servo / trim tab See shaded items below & Refer to KAI 2 AST Hinge HS-1218A / HS-1218B
5-7
Rev. 6
LANDING GEAR The landing gear includes the gear-legs, wheels and tires, nose fork and mounting brackets. The nose gear-leg is steel, with welded brackets. The aluminum nose fork attaches and pivots at the lower end. An axle bolt and nut fastens the axle, spacer, and wheel and tire assembly to the nose fork. The main gear-legs are aluminum, fastened to the center section channel with brackets and bolts. Each main axle bolts to the lower end of each gear leg. All three tires are 5.00 x 5 size, either 4-ply or 6-ply tube type aircraft tires are acceptable.
Figure 12: Landing Gear
5-8
Rev. 6
COMPONENTS Quantity Part or Assembly Name Part Number or Reference 1 Left Main Gear U-1220-L 1 Right Main Gear U-1220-R 2 Outbd Main Gear Attach Brkt U-1202 2 Outbd Doubler Plate U-1202C 2 Outbd Wear Plate U-1202D 2 Inbd Main Gear Attach Brkt U-1203 2 Inbd Wear Plate U-1203B 2 Doubler Plate U-1203C 2 Inbd Doubler Plate 2 Main wheel assembly See shaded items below 1 Main wheel U-MHMHE51B 2 Wheel bearings BEARING LM-67000L-A 1 Axle MHE51B AXLE 1 Nose gear WD-1201 1 Nose fork WD-1230-1 1 Nose wheel assembly See shaded items below 1 Nose wheel U-WHLNW51CC.625 1 Axle U-1210A-1 2 Spacer U-1210B-1 4 Wave washer 5806-148-3 1 Wheel bearing N/A 3 Tire U 5.00 X 5 TIRE 3 Tube U 5:00X5-6IT
5-9
Rev. 6
NOSE WHEEL AND GEAR LEG FAIRINGS The optional nose wheel and gear leg fairings include the glass fabric/epoxy resin nose leg fairing, wheel fairing front and the wheel fairing aft. See Figure 13. The nose leg fairing is clamped about the nose leg using a piano hinge held in place by a single screw. The nose leg fairing is slotted to fit about the nose leg winch lug. The wheel fairing aft attaches to the wheel fairing front which in turn attaches to the nose fork. Tow bar access is provided by two 13/16 diameter holes in the wheel fairing front.
Figure 13: Nose Wheel and Gear Leg Fairings
OPTIONAL COMPONENTS Quantity Part or Assembly Name Part Number or Reference 1 Wheel Fairing Front U-00005A 1 Wheel Fairing Aft U-00005B 1 Nose Leg Fairing U-00007
5-10
Rev. 6
WHEEL FAIRINGS The optional main wheel fairings include the glass fabric/epoxy resin wheel fairing front and the wheel fairing aft. See Figure 14. The fairings are attached to the wheel fairing brackets which in turn attach to the bracket mount.
Figure 14: Main Wheel Fairings
OPTIONAL COMPONENTS Quantity Part or Assembly Name Part Number or Reference 2 Wheel Fairing Front U-00001A 2 Wheel Fairing Aft U-00001B 4 Wheel Fairing Bracket U-00002 2 Bracket Mount (inner) not shown U-00003 2 Bracket Mount (outer) U-00004
5-11
Rev. 6
SERVICE
SUPPLIES
TOOLS EXPENDABLE
Needle nose pliers Cotter pins Sockets: Safety wire ▪ 3/8 Wheel bearing grease ▪ 5/16 Spray lubricant ▪ 7/16 Inner tube ▪ 1/2 Hydraulic fluid ▪ 9/16 Loctite ▪ 3/4 ▪ 1 1/2 ▪ 11 mm REPLACEABLE Combination wrenches: See component lists on page: ▪ 3/8 ▪ 5-3 ▪ 7/16 ▪ 5-9 ▪ 1/2 Canopy struts ▪ 9/16 Bearing MD3614M Allen wrenches: Bearing DW4K2X ▪ 3/16 Nose wheel bearings ▪ 1/4 Main wheel bearings ▪ 5/16 Nose fork bushings Screwdriver: Pivot guide ▪ #2 Phillips Upper rudder hinge Mallet Lower rudder hinge Large wooden dowel ▪ 1 1/2 - 1 3/4 inch dia. Small wooden dowel ▪ 1/2 - 1 inch dia. 2 1/2x3/16 bolt, washer, and nut Tensile weight scale
5-12
Rev. 6
GENERAL
WING REMOVAL No tools or certification required. ■ CAUTION: BE PREPARED WITH A HELPER OR SUPPORT STAND TO HANDLE THE WEIGHT AND AWKWARDNESS OF THE OBJECT TO BE REMOVED. ■ CAUTION: ALWAYS SUPPORT THE FLAPERON DURING WING REMOVAL AND STORAGE. 1. Retract the fuselage pin stopper on each fuselage pin and withdraw each of them only enough to release the right wing spar. (Note: rotating the pin back and forth while pulling makes removal easier). 2. Grasp the wing at the wing tip end, lift very slightly and pull to remove it from the fuselage and set it aside. 3. Fully remove both of the fuselage pins. 4. Remove the left wing using the same procedure and set aside.
● NOTE: THE OPTIONAL AOA SYSTEM PLUMBING MUST PASS A LEAK TEST DURING
EVERY INSPECTION AND EVERY TIME THE WINGS ARE REMOVED AND INSTALLED.
INSTALLATION 1. Installation procedure is the reverse of the removal procedure. (install left wing first, right wing second). The wing root seal strip on the side of the fuselage can be used to help align the wing at the proper angle of attack while inserting it into the fuselage. The root end of the flaperon must be properly aligned with the clevis portion of the flaperon torque tube for the wing to fully insert. (Note: rotating the pin while pushing with the heal of your palm helps aid in pin insertion.)
WING RETENTION PIN BUSHING REPLACEMENT Tools Mallet Large wooden dowel, 1 1/2 - 1 3/4 inch dia. Expendable None Replaceable Wing Retention Pin Bushing Service Rating Preventative Minimum Certification Owner, LSA-RM, or A&P Additional KAI References 1. Remove the wings.
5-13
Rev. 6
IN CENTER SECTION: 1. Tap out the bushing from the non-flanged end of the bushing. 2. Tap the new bushing into place with the flanged end toward the wing spars.
IN WING SPARS: 3. Tap out the bushing from the non-flanged end of the bushing. 4. Tap the new bushing into place with the flanged end to be on the forward side of the wing spar.
CANOPY AND FRAME REMOVAL Tools 7/16 socket Expendable None Replaceable Canopy and Frame Canopy struts Service Rating Line Minimum Certification LSA-RM or A&P Additional KAI References
■ CAUTION: BE PREPARED WITH A HELPER OR SUPPORT STAND TO HANDLE THE WEIGHT AND AWKWARDNESS OF THE OBJECT TO BE REMOVED.
1. Open and support the canopy. (Easiest with a partner) 2. Remove the strut hardware; bolts (2). 3. Remove the pivot hardware; bolts (2), and bushings (2). 4. Remove canopy and frame.
INSTALLATION
■ CAUTION: DO NOT OVERTIGHTEN THE CANOPY STRUT HARDWARE. ALLOW THE CANOPY STRUT APPROXIMATELY 1/64 INCH OF TOTAL MOVEMENT ALONG THE BOLT SHANK.
1. Installation procedure is reverse of the removal procedure.
5-14
Rev. 6
MAIN WHEEL AND TIRE ASSEMBLY REMOVAL Tools Needle nose pliers 1 1/2, 7/16 socket Expendable Cotter pins Safety wire Replaceable None Service Rating Preventative Minimum Certification Owner and SPC, LSA-RM, or A&P Additional References Matco user manual KAI
1. Lift and support the aircraft. (1-16) 2. Remove the stationary brake shoe bolts (2), washers (2), spacer and brake shoe. 3. Remove the cotter pin, axle nut, washer and wheel and tire assembly.
INSTALLATION 1. Installation procedure is reverse of the removal procedure.
5-15
Rev. 6
NOSE WHEEL AND TIRE ASSEMBLY REMOVAL Tools 9/16 socket 9/16 combo wrench Expendable None Replaceable None Service Rating Preventative Minimum Certification Owner and SPC, LSA-RM, or A&P Additional References Matco user manual KAI 1. Lift and support the aircraft. (1-16) 2. Remove the axle bolt, washers (2), nut, axle, spacer, and wheel and tire assembly.
INSTALLATION 1. Installation procedure is reverse of the removal procedure.
MAIN INNER TUBE REPLACEMENT Tools 1/2 socket 3/16, 1/4 Allen Expendable Inner tube Safety wire Replaceable Main wheel assembly Tire Service Rating Preventative Minimum Certification Owner and SPC, LSA-RM, or A&P Additional Matco user manual References KAI 1. Lift and support the aircraft. (1-16) 2. Remove the main wheel and tire assembly. (5-15) 3. Remove the brake disc socket-head cap screws (3), and brake disc. 4. Deflate the inner tube. 5. Split the wheel assembly by removing the socket head cap screws (6), washers (9), and nuts (6). 6. Replace the inner tube. Orient the valve stem to the hole in the wheel and the colored dot on the tire. 7. SLOWLY inflate the tire. Deflate it fully and re-inflate it SLOWLY a couple more times to work out any wrinkles in the tube. Inspect for a good seat around the wheel rim. For final inflation pressure see page 1-14. 8. Reassemble and install the wheel and tire assembly.
5-16
Rev. 6
NOSE INNER TUBE REPLACEMENT Tools 3/16 Allen Expendable Inner tube Replaceable Nose wheel assembly Tire Service Rating Preventative Minimum Certification Owner and SPC, LSA-RM, or A&P Additional References Matco user manual KAI
Lift and support the aircraft. (1-16) 1. Remove the nose wheel and tire assembly. (5-16) 2. Deflate the inner tube. 3. Split the wheel assembly by removing the bolts (3), washers (6), and nuts (3). 4. Replace the inner tube. Orient the valve stem with the hole in the wheel and the colored dot on the tire. 5. SLOWLY inflate the tire. Deflate it fully and re-inflate it SLOWLY a couple more times to work out any wrinkles in the tube. Inspect for a good seat around the wheel rim. For final inflation pressure see page 1-14. 6. Reassemble and install the wheel and tire assembly.
FLAPERON HINGE REPLACEMENT Tools 3/8 socket 3/8 combo wrench Expendable None Replaceable Bearing MD3614M Service Rating Line Minimum Certification LSA-RM or A&P Additional References KAI
■ CAUTION: BE PREPARED WITH ADDITIONAL PERSONEL OR TOOLS TO HANDLE THE WEIGHT AND AWKWARDNESS OF THE OBJECT TO BE REMOVED.
1. Remove the wings. (5-13) 2. Make note of the flaperon hinge hardware configuration 3. Remove the flaperon hardware and flaperon assembly.
5-17
Rev. 6
4. Measure and record the hinge bearing protrusion measurement as shown in Figure 15.
Figure 15: Flaperon hinge
5. Remove the flaperon hinge bearing from the wing. 6. Install the new flaperon hinge bearing to the same protrusion measurement. 7. Install the flaperon assembly.
RUDDER HINGE REPLACEMENT Tools 3/8 socket 3/8 combo wrench #2 Phillips screwdriver Expendable None Replaceable Lower rudder hinge Upper rudder hinge Service Rating Line Minimum Certification LSA-RM or A&P Additional References KAI
■ CAUTION: BE PREPARED WITH ADDITIONAL PERSONEL OR TOOLS TO HANDLE THE WEIGHT AND AWKWARDNESS OF THE OBJECT TO BE REMOVED.
1. Remove the upper and lower tailcone fairing. (3-4) 2. Remove the rudder control cables and rudder assembly. 3. Remove, from the vertical stabilizer, the rudder hinge hardware (see below) and the rudder hinge to be replaced; Upper hinge; bolt (4), washer (8) Lower hinge; bolt (4), washer (4)
5-18
Rev. 6
■ CAUTION: UPPER AND LOWER RUDDER HINGES ARE NOT INTERCHANGABLE.
4. Install the new rudder hinge and hardware. 5. Install the rudder assembly. 6. Install the upper and lower tailcone fairing.
STABILATOR HINGE REPLACEMENT Tools 1/4 drive socket slightly less than 5/8in in diameter. A common standard 7/16 socket generally works. 3/8 drive 3/4 socket Screwdriver 3/8 Wrench 7/16 socket, ratchet and extension Needle nose pliers
Hex Bolt 1/4 diameter 3 inches long (must be threaded at least 50% of its length)
1/4 Flat Washer(2) and Hex Nut Expendable Cotter pins Lock Clips (2) Loctite 648 Replaceable Bearing DW4K2X Service Rating Line Minimum Certification LSA-RM or A&P Additional KAI References
■ CAUTION: BE PREPARED WITH ADDITIONAL PERSONEL OR TOOLS TO HANDLE THE WEIGHT AND AWKWARDNESS OF THE OBJECT TO BE REMOVED. Removing the Stabilator 1. Remove the upper and lower tailcone fairing. (3-4)
● NOTE: BEFORE DISCONNECTING THE STABILATOR CONTROL CABLES BE PREPARED TO PREVENT THE ENDS OF THE CABLES FROM FALLING INTO THE TAILCONE.
2. Remove the two aft most belly inspection covers.
5-19
Rev. 6
3. Remove the Lock Clips from one of the cable tensioners. 4. Rotate the tensioning barrel to slacken the stabilator control cables. 5. Disconnect the stabilator control cables. 6. Disconnect the aft end of the Trim/Servo Pushrod from the Anti-servo Tabs. 7. Remove the two bolts attaching the counter balance arm to the stabilator. 8. Remove the two bolts attaching the stabilator to the aft end of the tail cone. 9. Remove the stabilator assembly. Note: while extracting the counterbalance arm from the fuselage, rotate the counter balance arm 90 degrees to allow it to pass through the aft tailcone bulkhead.
Bearing Replacement 10. Pressing out the bearing: Position the sockets on each side of the bearing then use the nut, washer and bolt inserted through both sockets and the bearing. Tighten the nut on the bolt to press the bearing towards the large socket. See Figure 16.
Figure 16: Extracting the DW4K2X bearing
11. Carefully clean the new bearing and the inner bore of the VA-146A Flange Housing using denatured alcohol. After cleaning, handle the bearings with care as to not re-contaminate the outer surface. 12. Insert a bearing into the VA-146A Flange Housing with minimal engagement just far enough that the bearing aligns itself with the center hole in the flange. 13. Place a bead of Loctite 648 onto the outer surface of the bearing around the entire circumference next to the edge of the VA-146A Flange Housing. 14. Pressing in the bearing: Using the same process as removing, use the small socket to press the bearing towards the large socket and into the VA-146A Flange Housing until the bearing is flush on both sides. Allow the Loctite sufficient time to cure per instructions on the package. 15. After reinstalling the stabilator readjust the stabilator control cable tensions in accordance with the KAI and install new lock clips on the adjuster barrel.
■ CAUTION: BE SURE TO RE-ORIENT THE COUNTERBALANCE ARM SO THAT THE COUNTERBALANCE WEIGHT IS POSITIONED CORRECTLY. REFER TO KAI
5-20
Rev. 6
MAIN GEAR REMOVAL Tools 7/16, 1/2, 9/16 socket 7/16, 1/2, 9/16 combo wrench Expendable Hydraulic fluid Replaceable Left Main Gear Right Main Gear Outbd Main Gear Attach Brkt Outbd Wear Plate Inbd Main Gear Attach Brkt Inbd Wear Plate Service Rating Line Minimum Certification LSA-RM, or A&P Additional References KAI Matco user manual 1. Lift and support the aircraft. (1-16) 2. Remove the two outboard center section Cover Plates on the belly. (3-4) 3. Drain the hydraulic fluid. (7-5) 4. Disconnect the brake line at the main gear attach bracket. 5. Remove the center bolt, washer, and nut from the inboard main gear attach bracket. 6. Loosen the remaining inboard and outboard attach bracket hardware. 7. Remove the main gear-leg.
INSTALLATION 1. Installation procedure is reverse of the removal procedure. 2. Add hydraulic fluid and bleed the brake system. 3. Torque all landing gear attach hardware. Remember to account for prevailing torque.
NOSE GEAR REMOVAL Tools 3/8, 9/16 socket Needle nose pliers Expendable Cotter pins Replaceable None Service Rating Line Minimum Certification LSA-RM, or A&P Additional References KAI
1. Remove the top and bottom cowl. (3-4) 2. Lift and support the aircraft. Place an additional support stand at the tail tie down. (1-16)
5-21
Rev. 6
▲ WARNING: DO NOT REMOVE THE UPPER VIBRATION-ISOLATOR BOLTS.
3. Remove the lower engine vibration-isolator bolts (2). 4. Remove the nose gear-leg hardware from the fuselage; bolts (13) and washers (13).
● NOTE: THE ENGINE CAN BE LIFTED BY HAND AT THE GEARBOX.
5. Lift the front of the engine only enough to remove the engine weight from the gear-leg bracket. 6. Remove the nose gear-leg.
INSTALLATION 1. Lift the front of the engine only enough to provide room behind the engine mount for the nose gear-leg. 2. Install the nose gear-leg and attach hardware. 3. Install the lower engine vibration isolator bolts.
BELT AND HARNESS REPLACEMENT Tools 7/16 socket 7/16 combo wrench Expendable None Replaceable Occupant Harness Service Rating Preventative Minimum Certification Owner and SPC, LSA- RM, or A&P Additional References KAI
▲ WARNING: HARNESS PARTS THAT SHOW ANY SIGN OF WEAR REQUIRE THAT THE ENTIRE HARNESS SET BE REPLACED IMMEDIATELY. 1. Remove the seat ramp cover. (3-4) 2. Remove the crotch strap; bolt, bushing, washer, nut. 3. Remove each waist strap (2); bolt, bushing, washer, nut. 4. Remove the shoulder straps; bolt, bushing, washer, nut. 5. Install the new harness set and attach hardware.
5-22
Rev. 6
CANOPY LATCH BLOCK REPLACEMENT Tools #2 Phillips screwdriver Expendable None Replaceable Latch Block Service Rating Line Minimum Certification LSA-RM, or A&P Additional References KAI 1. Remove the latch block attach screws (2) and the latch block. 2. Install the new latch block and attach hardware.
STEP REPLACEMENT Tools 7/16 socket Expendable None Replaceable Left or Right Step Service Rating Preventative Minimum Certification Owner, LSA-RM, or A&P Additional References KAI 1. Remove the step attach bolts (2), washers (2) and the step. 2. Install the new step and attach hardware.
REAR SPAR DOUBLER REPLACEMENT Tools #30 drill bit, drill, clecos, rivet puller, rivet squeezer & dies Expendable sandpaper Replaceable Left or Rt. Rear Spar Doubler Service Rating Line Minimum Certification LSA-RM, or A&P Additional References KAI 1. Based on the measurement from Section 3, Inspection, chose one of the replacement W-1207B-x rear spar doublers. There are four different ones available, ranging from 0.025 to 0.055 longer than the original, in increments of 0.010 — (i.e: W-1207-25 is 0.025” longer than stock.) Note that a pattern of holes punched in the inboard end indicates the size – one extra hole is the first oversize then two, three and four holes are used to identify each progressively longer part. 2. Prepare the doubler by sanding the rounded end just enough to remove the rough surface left from manufacture, no more. 3. Prime the doubler if/as desired. 4. Remove the wing and drill out the rivets attaching the W-1207B rear spar doubler, W-1212 and hinge assembly to the rear spar. See KAI Section 5.4.
5-23
Rev. 6
5. Drill the holes in the new doubler to #30 (except the identifier holes) and cleco it to the rear spar. 6. Test fit the wing with the new doubler clecoed in place (the hinge assembly does not need to be in place for this step.) If the fit is too tight, remove the wing, un- cleco the doubler and sand the contour of the curve 0.010” or less and test fit again. Repeat until the correct fit is achieved. 7. Rivet the doubler and hinge assembly to the spar as shown below
Figure 16.1: Rear Spar Doubler Replacement
5-24
Rev. 6
SERVICE SCHEDULE PROCEDURES
WING ATTACH LOCATION LUBRICATION (WINGS REMOVED) Tools None Expendable Wheel bearing grease Anti-seize compound Replaceable Fuselage Pin Service Rating Preventative Minimum Certification Owner and SPC, LSA-RM, or A&P Additional References KAI
FUSELAGE PINS 1. Wipe clean, the fuselage pins (2). 2. Wipe clean, the wing retention pin bushings (8). 3. Apply grease lubricant sparingly to the shaft of each fuselage pin.
STUB SPAR AND REAR SPAR 1. Wipe clean, the inboard end of the stub spar and rear spar of each wing. (5-4) 2. Apply anti-seize compound sparingly to the inboard end of the stub spar and rear spar of each wing.
FLAPERON CONTROL CONNECTION LUBRICATION (WINGS REMOVED) Tools None Expendable Wheel bearing grease Replaceable None Service Rating Preventative Minimum Certification Owner and SPC, LSA-RM, or A&P Additional References KAI Wing removal (5-13)
1. Wipe clean, the UHMW pivot guide and actuation bracket of each flaperon. See page 5-4, Figure 10. 2. Apply lubricant sparingly to the UHMW pivot guide and actuation bracket of each flaperon.
5-25
Rev. 6
FLAPERON BEARINGS LUBRICATION Tools None Expendable Spray lubricant Replaceable None Service Rating Preventative Minimum Certification Owner and SPC, LSA-RM, or A&P Additional References KAI Flaperon hinge replacement (5-17) 1. Wipe away any dirt accumulation from each of the flaperon bearings (3). 2. Apply lubricant sparingly to each of the flaperon bearings. 3. Allow lubrication to penetrate for a minute or more. Wipe away excess.
ANTI-SERVO TAB ATTACH HINGE LUBRICATION Tools None Expendable Spray lubricant Replaceable None Service Rating Preventative Minimum Certification Owner and SPC, LSA-RM, or A&P Additional References KAI 1. Lower the Anti-Servo Tab by adjusting the trim. Lower the trailing edge of the stabilator. 2. Wipe away any dirt accumulation from the AST attach hinges. 3. Apply lubricant along the top of the left and right AST attach hinges. 4. Allow lubrication to penetrate for a minute or more. Wipe away excess.
NOSE WHEEL BEARINGS REPLACEMENT
■ CAUTION: THE NOSE WHEEL BEARINGS ARE NOT SERVICEABLE PARTS.
Tools 3/16 Allen Small wooden dowel, 1/2 - 1 inch dia. Mallet Expendable None Replaceable Wheel bearings Service Rating Preventative Minimum Certification Owner, LSA-RM, or A&P Additional References Matco user manual 1. Lift and support the aircraft. (1-16) 2. Remove the nose wheel and tire assembly. (5-16) 3. Deflate the inner tube.
5-26
Rev. 6
4. Split the wheel and tire assembly by removing the bolts (3), washers (6), and nuts (3). 5. Press the wheel bearing out from the inside of each wheel half. 6. Press a new wheel-bearing into each wheel half. 7. Reassemble the wheel and tire assembly. 8. SLOWLY inflate the tire. Deflate it fully and re-inflate it SLOWLY a couple more times to work out any wrinkles in the tube. Inspect for a good seat around the wheel rim. The final inflation pressure is 15 psi. 9. Install the wheel and tire assembly.
MAIN WHEEL BEARINGS LUBRICATION Tools 1 1/2 socket Needle nose pliers Expendable Wheel bearing grease Replaceable Wheel bearing Service Rating Preventative Minimum Certification Owner and SPC, LSA-RM, or A&P Additional References Matco user manual 1. Lift and support the aircraft. (1-16) 2. Remove the main wheel and tire assembly. 3. Remove and clean the main wheel bearings (2). 4. Apply wheel-bearing grease to each of the bearings. 5. Install the wheel-bearings. 6. Install the wheel and tire assembly.
5-27
Rev. 6
NOSE FORK PIVOT TENSION AND LUBRICATION Tools Needle nose pliers 1 1/2 socket Tensile weight scale Expendable Waterproof wheel bearing grease Replaceable Nose fork bushings Service Rating Line Minimum Certification LSA-RM, or A&P Additional References KAI 1. Lift and support the aircraft. (1-16) 2. Remove the nose fork and attach hardware; cotter pin, nut, washer, spring washers (2). 3. Clean the end of the nose gear leg and the nose fork bushings. 4. Apply a liberal amount of marine trailer (or waterproof equivalent) wheel bearing grease to the nose fork bushings. 5. Installation procedure is reverse of the removal procedure. 6. Tighten the nut until a push or pull force of 18-20 lbs applied at the axle is measured while the nose fork is rotated around the end of the nose gear leg.
5-28
Rev. 6
TIRE ASSEM. BALANCING PROCEDURE ● NOTE:IT IS NOT A MAINTENANCE REQUIREMENT THAT THE NOSE OR MAIN WHEEL/TIRE ASSEMBLIES ON THE RV-12 BE BALANCED, BECAUSE OF THE RELATIVELY LOW TAKEOFF AND LANDING SPEED. SHOULD A VIBRATION BE DETECTED THAT IS SUSPECTED TO BE CAUSED BY A WHEEL/TIRE IMBALANCE, THIS PROCEDURE MAY BE USED.
1. Remove the suspected out of balance wheel/tire assembly(s) from the aircraft. 2. Mount the Wheel/Tire assy. in a static balance test stand and allow the assy. to rotate to the heavy side down position. 3. A.) Main Wheel assy. - Use tape to temporarily add stick on wheel weights (obtain from a local automotive store commonly available wheel weights with self-adhesive) to the outboard wheel flange, opposite the heavy point of the wheel, until the assy. can be moved to any rotational position without it rotating. Mark the position of the wheel weights and then remove them. Thoroughly clean the area of the wheel flange where the wheel weights will be located. Remove the protective backing and press the wheel weights in place on the wheel flange. B.) Nose Wheel assy. - Use tape to temporarily add stick on wheel weights to the interior area of the nose wheel (working through the lightening holes in the wheel). If the proper weight location coincides with one of the three wheel through bolts, distribute the weight, as close as possible, to each side of the through bolt. Thoroughly clean the interior area of the wheel where the wheel weights will be located. Remove the protective backing and press the wheel weights in place on the interior area of the wheel. 4. Re-install the wheel assy. on the aircraft.
5-29
Rev. 6
THIS PAGE INTENTIONALLY LEFT BLANK
5-30
Rev. 4
CHAPTER 6 - FLIGHT CONTROLS
OVERVIEW ...... 6-2 Components ...... 6-2 SERVICE ...... 6-3 Supplies ...... 6-3 Tools ...... 6-3 Expendable ...... 6-3 Replaceable ...... 6-3 General ...... 6-3 Stabilator pulley replacement and cable tension adjustment ...... 6-3 Control cable replacement ...... 6-6 Rod end replacement ...... 6-7 Bellcrank bearing replacement ...... 6-8 Rudder pedal removal ...... 6-8 Installation ...... 6-9 Service Schedule Procedures ...... 6-9 Control system rod end lubrication ...... 6-9 Cable end hardware lubrication ...... 6-9
6-1
Rev. 4
OVERVIEW The control system enables the pilot to operate the control surfaces. Forward or aft movements of the control stick control the pitch. The pitch control linkage is a pair of cables, each routed around a pulley. An electronic switch wired to the pitch-trim servo, controls the pitch-trim. Side-to-side movements of the control stick controls roll via push rods, a bell crank, and torque tubes. Rudder pedals control yaw via cables to the rudder. Refer to the KAI to identify the individual parts and part #’s of the control system.
• NOTE: This maintenance manual is intended to be used in conjunction with the RV-12 Kit Assembly Instructions (KAI) when completing maintenance or repair processes.
COMPONENTS Quantity Part or Assembly Name Part Number or Reference 1 Flap handle / Pushrod Refer to KAI 1 Flaperon Mixer Bellcrank F-1263A & F-1263B 2 Control stick pushrod Refer to KAI 2 Control stick WD-1212 2 Flaperon pushrod Refer to KAI 1 Left flaperon torque arm Refer to KAI 1 Right flaperon torque arm Refer to KAI 2 Stabilator cable F-1247A & B 2 Rudder cable F-1239 2 Rudder pedal WD-1206 2 Stab cable pulley MS24566-4B 4 Locking clips MS21256-1 1 Pitch / Trim servo See Chapter 8 Optional Components 1 Autopilot Module IF Dynon AP AP74V-12 or SV-AP-PANEL and SV-KNOB-PANEL or Garmin GMC 305 1 Autopilot (Pitch) Servo IF DYNON AP SV32 or Garmin GSA 28 1 Autopilot (Roll) Servo IF DYNON AP SV32 or Garmin GSA 28
6-2
Rev. 4
SERVICE Annual lubrication will maximize the longevity of the control system. Refer to the service schedule checklist for the specific service frequency of the components. See Supplement for service schedule checklist.
SUPPLIES
TOOLS EXPENDABLE
Needle nose pliers Cotter pins Socket: Safety wire ▪ 11/32 Spray lubricant ▪ 3/8 ▪ 7/16 REPLACEABLE ▪ 3/4 Stabilator pulley ▪ 11 mm Lock clips Combination wrench: Stabilator cables ▪ 3/8 Rudder cables ▪ 7/16 Bearing #DW4K2X (Bellcrank) Screwdriver: Rod ends: ▪ #2 Phillips ▪ Control Stick: M3414 / CM-4MS 2 1/2x3/16 bolt, washer, and ▪ Flap Handle: CM-4M nut ▪ Flaperon: F3514M Cable tension meter ▪ Trim/Servo: MM-3 Spring clamps (3) Rudder pedal Stick, 41" long
GENERAL
STABILATOR PULLEY REPLACEMENT AND CABLE TENSION ADJUSTMENT Tools 3/8, 7/16 socket 3/8, 7/16 combo wrench Needle nose pliers Cable tension meter Spring clamps (3) Stick, 41" long Expendable Cotter pins, Lock clips Replaceable Stabilator pulley Service Rating Line Minimum Certification LSA-RM, or A&P Additional References KAI
6-3
Rev. 4
1. Remove the seat ramp cover and cover plate (only the aft two). (3-4)
2. Remove the stabilator control cable barrel lock clips from one barrel as shown in Figure 17.
Figure 17: Locking clip removal
3. Loosen the tension of the stabilator cables by turning the tensioner barrel as shown in Figure 18.
Figure 18: Tensioner barrel removal 4. Remove the pulley axle hardware and pulleys. 5. Capture the stabilator cables between the bushing and the new pulleys. 6. Install the pulley axle hardware. 7. Place a small weight on the stabilator to hold it trailing edge down. Remove the slack from the upper cable by tightening the upper (outboard) turnbuckle until the control stick and stabilator just start to lift off the stops at about the same time when the stick is moved aft.
Remove the slack from the other cable by adjusting the lower (inboard) turnbuckle. Check the entire length of the cables to ensure they are free from interference, are properly aligned in the pulleys, and do not touch each other. Pull the stick aft to make sure that the stabilator trailing edge moves up. NOTE: The F-1227 Seat Ramp Cover must be installed prior to adjusting the cable tension.
6-4
Rev. 4
8. Install the F-1227 Seat Ramp Cover (refer to KAI). If the four screw holes for the F-1233 Control Column Mount Brackets (refer to KAI) do not align with the cover, a light upward pull on the stick will correct the misalignment until the screws are inserted and tightened.
NOTE: Cable tension will change significantly with changing temperature. The cable tensions given below are for an aircraft inside a 70 OF hanger.
9. Position one of the WD-1212 Control Sticks so that the top end is 10 inches from the instrument panel. Secure the control stick in place using a spring clamp to attach it to a 41" long stick bridged between and clamped to the upper longerons.
Check the cable tension just aft of the F-1207B Baggage Bulkhead using a calibrated cable tension meter making sure the control stick is correctly positioned.
Adjust turnbuckles an equal number of turns each to achieve 35-45 lbs of tension with the groove in the cable ends aligned with a V-notch in each turnbuckle barrel as shown in Figure 17. This tension will prevent the cables from "slapping" against the tailcone bulkheads when the control sticks are moved suddenly and repeatedly forward then aft.
10. Remove the clamp and stick from the control stick and the weight from the stabilator.
Move the control stick between the forward and aft pitch stops. The stabilator should reach its travel stops just before the corresponding control stick stops are reached. If not, adjust the turnbuckles an equal and opposite number of turns until this is achieved. (Example: If the stabilator reaches its T.E. up stop too soon loosen the upper turnbuckle and tighten the lower turnbuckle. This will lengthen the upper cable and shorten the lower cable). After making adjustments repeat step 6 to reconfirm proper cable tension.
11. Once the proper tension is achieved, and no more than three threads are exposed from the ends of the barrels, align the V-notch in the ends of the barrel with the groove in the cable ends and then insert the lock clips as shown in Figure 17. The hook end of the lock clips are inserted into the hole in the center of the barrel and must be completely pressed in until the hook springs open inside the barrel.
6-5
Rev. 4
CONTROL CABLE REPLACEMENT ■ CAUTION: THE CONTROL SURFACE WILL SWING FREELY WHEN THE CONTROL CABLES ARE REMOVED. ● NOTE: ALWAYS REPLACE CONTROL CABLES AS A SET.
Tools 3/8, 7/16 socket 3/8, 7/16 combo wrench Needle nose pliers String Cable tension meter Spring clamps (3) Stick, 41" long Expendable Cotter pins Lock clips Replaceable Stabilator cables Rudder cables Service Rating Line Minimum Certification LSA-RM, or A&P Additional References KAI 1. Remove the tunnel cover, step floor cover, seat ramp cover, seat floor cover, cover plate (only the aft two), baggage cover, baggage bulkhead corrugation, upper tailcone fairing, lower tailcone fairing, fuel tank assembly. (3-4) 2. For rudder cable, remove the rudder cable sleeve attach hardware; bolts (3), washers (3), nuts (3). 3. For the stabilator cable, remove the tensioner barrels and stabilator pulleys. (6-4)
● NOTE: TIE A STRING, LONGER THAN THE CONTROL CABLE, TO THE AFT END OF THE CONTROL CABLE AND WRAP THE SAME END OF THE CONTROL CABLE WITH A PIECE OF TAPE TO AVOID BULKHEAD DAMAGE.
4. Disconnect the attach hardware (see below) at the forward and aft end of the cable to be removed. Rudder cable end hardware: Fwd; bolt, washer, nut, and cotter pin. Aft; bolt, washers (3), nut, and cotter pin. Stabilator cable end hardware: Fwd; bolt, washer (2), nut, and cotter pin. Aft; bolt, washers (3), nut, and cotter pin. 5. Pull the cable out from the opposite end of the string. Remove the cable, leaving the string in its place. 6. Tie the new cable to the end of the string and cover the end with a piece of tape.
6-6
Rev. 4
● NOTE: THE SEAT RAMP COVER MUST BE INSTALLED PRIOR TO ADJUSTING THE CABLE TENSION.
7. Installation procedure is reverse of the removal procedure. 8. Adjust cable tension as described earlier in this chapter.
ROD END REPLACEMENT Tools 3/8, 7/16 socket 3/8, 7/16 combo wrench Expendable Cotter pins Replaceable Applicable rod end Service Rating Line Minimum Certification LSA-RM, or A&P Additional References KAI 1. Remove applicable combination of the seat ramp cover, seat floor cover, baggage cover, and fuel tank assembly. (3-4) 2. Remove the control rod attach hardware from the rod end for replacement; Control stick – control stick pushrod: bolt, washers (3), and nut. Control stick pushrod – bellcrank: washer and nut. Bellcrank – flap handle pushrod: bolt and washers (2). Bellcrank – flaperon pushrod: bolt, washer and nut. Flaperon pushrod – flaperon torque arm: bolt, washers (2) and nut. 3. Make note of the number of threads exposed on the rod end shaft and the clocking of the bearing body. 4. Remove the rod end and jam nut. 5. Add a jam nut to the new rod end shaft. 6. Install the new rod end to the position (from step 3) of the original rod end. 7. Install the control rod and control rod attach hardware.
6-7
Rev. 4
BELLCRANK BEARING REPLACEMENT Tools 3/8, 7/16, 3/4, 11 mm socket 3/8, 7/16 combo wrench 2 1/2x3/16 bolt, washer, and nut Expendable None Replaceable Bearing DW4K2X Service Rating Line Minimum Certification LSA-RM, or A&P Additional KAI References
1. Remove the seat ramp cover and seat floor cover. (3-4) 2. Remove the pushrod-to-bellcrank hardware: Control stick pushrod: washer and nut Flap handle pushrod: bolt and washers (2) Flaperon pushrod: bolt, washer and nut 3. Remove the bellcrank. 4. Use the same method instructed for extracting the DW4K2X hinge bearing on page 5-20, Figure 16. 5. Installation procedure is reverse of the removal procedure.
RUDDER PEDAL REMOVAL Tools 11/32, 3/8 socket 3/8 combo wrench Needle nose pliers #2 Phillips screwdriver Expendable Cotter pins Replaceable Rudder pedal Service Rating Line Minimum Certification LSA-RM, or A&P Additional References KAI Matco user manual 1. Remove the tunnel cover. (3-4) 2. Remove the rudder pedal access covers (directly aft of the horizontal tubes of the rudder pedals) and hardware; screws (3), washers (2) and nuts (2).
● NOTE: THE MASTER CYLINDERS CAN BE REMOVED WITHOUT DISCONNECTING THE BRAKE LINES.
3. Label, and then remove the master cylinders (4) from the rudder pedals. (7-3) 4. Remove the rudder cable hardware from each rudder cable; cotter pin, bolt, washers (3) and nut.
6-8
Rev. 4
5. Remove the rudder pedal-block hardware; bolts (2) and washers (2), from each of the rudder pedal-blocks (3). 6. Remove rudder pedal assembly.
INSTALLATION 1. Installation procedure is reverse of the removal procedure.
SERVICE SCHEDULE PROCEDURES
CONTROL SYSTEM ROD END LUBRICATION Tools #2 Phillips 3/8, 7/16 sockets Expendable Spray lubricant Replaceable None Service Rating Line Minimum Certification LSA-RM, or A&P Additional References KAI
1. Remove the seat ramp cover, seat floor cover, baggage cover, and fuel tank assembly. (3-4) 2. Apply lubricant sparingly to the rod-end bearings on each end of the following components: Flap handle pushrod Control stick pushrod Flaperon pushrod Trim / Servo pushrod 3. Allow lubrication to penetrate then wipe away excess. 4. Apply grease to F-1266AD Flap Detent Bracket.
CABLE END HARDWARE LUBRICATION Tools None Expendable Spray lubricant Replaceable None Service Rating Line Minimum Certification LSA-RM, or A&P Additional References KAI
1. Remove the tunnel cover, seat ramp cover, upper tailcone fairing, and lower tailcone fairing. (3-4) 2. Apply lubricant sparingly to the hardware at both ends of the rudder and stabilator control cables.
6-9
Rev. 4
THIS PAGE INTENTIONALLY LEFT BLANK
6-10
Rev. 2 CHAPTER 7 - BRAKE SYSTEM
OVERVIEW ...... 7-2 Components ...... 7-2 SERVICE ...... 7-2 Supplies ...... 7-3 Tools ...... 7-3 Expendable ...... 7-3 Replaceable ...... 7-3 General ...... 7-3 Master cylinder removal ...... 7-3 Removal ...... 7-3 Disconnection ...... 7-4 Installation ...... 7-4 Service Schedule Procedures ...... 7-4 Brake pedal torque tube lubrication ...... 7-4 Hydraulic fluid drain, flush, and replace ...... 7-5 Draining ...... 7-5 Flushing ...... 7-5 Replacing ...... 7-5 Brake lining replacement ...... 7-6
7-1
Rev. 2
OVERVIEW The brake system includes the necessary components to provide directional control and stopping ability while taxiing. The left and right brakes are independently controlled hydraulic disc brakes. The fluid reservoir supplies the master cylinders with hydraulic fluid. Pressure applied to either brake pedal causes the master cylinder to force hydraulic fluid through the plastic and aluminum lines to the corresponding brake caliper. Refer to the Matco instructions and the KAI to identify the individual parts of the brake system.
• NOTE: This maintenance manual is intended to be used in conjunction with the RV-12 Kit Assembly Instructions (KAI) when completing maintenance or repair processes.
COMPONENTS Quantity Part or Assembly Name Part Number or Reference 2 Disc and caliper Matco; Refer to KAI 4 Brake shoes Refer to Matco manual 4 Brake shoe linings Refer to Matco manual 4 Brake pedal WD-1209 2-L,2-R Brake pedal torque tube WD-1211-L & R 2 Left brake master cylinder BRAKE MAST CYL LEFT-1 2 Right brake master cylinder BRAKE MAST CYL RIGHT-1 1 Fluid Reservoir VA-107 2 Aluminum Line Refer to KAI 6 Plastic Line Refer to KAI
SERVICE Use of the proper hydraulic fluid is necessary for proper operation of the brake system. It is good practice to replace the hydraulic fluid every 5 years. If any indication of contamination is present, replace hydraulic fluid as soon as possible. Since the brakes on the RV-12 are relied on for part of the airplanes steering control on the ground, any detected leaks should be repaired prior to further flight. Refer to the service schedule checklist for component service frequency.
7-2
Rev. 2 SUPPLIES
■ CAUTION: USE ONLY MIL SPEC MIL-H-5606A HYDRAULIC FLUID! DO NOT USE AUTOMOTIVE BRAKE FLUID. DAMAGE TO O-RING SEALS MAY RESULT.
TOOLS EXPENDABLE Socket: Hydraulic fluid ▪ 3/8 Wheel bearing grease ▪ 7/16 Cotter pins Combination Wrench: Brake shoe linings ▪ 1/4 ▪ 3/8 REPLACEABLE ▪ 7/16 See component list on page 7-2. ▪ 1/2 Needle nose pliers Container
GENERAL
MASTER CYLINDER REMOVAL
■ CAUTION: THE LEFT AND RIGHT MASTER CYLINDERS ON EACH SIDE OF THE AIRCRAFT ARE NOT INTERCHANGABLE.
Tools 3/8 socket 3/8, 1/2 combo wrench Needle nose pliers Expendable Hydraulic fluid Cotter pins Replaceable Left/Right Brake master cylinder Service Rating Line Minimum Certification LSA-RM, or A&P Additional References KAI Matco user manual
REMOVAL 1. Remove the upper and lower master cylinder attach hardware. Upper: clevis pin, washer, and cotter pin. Lower: bolt, washer, nut, and cotter pin.
7-3
Rev. 2
DISCONNECTION 1. Drain the hydraulic fluid. (7-5) 2. Make note of the hose connections. 3. Disconnect brake lines from master cylinder.
INSTALLATION 1. Installation procedure is reverse of the removal procedure. 2. Bleed the brake system. (7-5)
SERVICE SCHEDULE PROCEDURES
BRAKE PEDAL TORQUE TUBE LUBRICATION Tools 7/16 socket 7/16 combo wrench Needle nose pliers Expendable Cotter pins Wheel bearing grease Replaceable None Service Rating Line Minimum Certification LSA-RM, or A&P Additional References KAI
● NOTE: SERVICE ONE PEDAL AT A TIME.
1. Actuate the rudder pedals so that the brake pedal to be serviced is offset from the adjacent rudder and brake pedal. The following steps relate to Figure 19. 2. Remove the master cylinder lower hardware. 3. Remove the brake pedal hardware; bolt, washer, and nut. Figure 19: Torque tube lubrication
7-4
Rev. 2
4. Remove the brake pedal from the pivot tube. 5. Remove the pivot tube from the rudder pedal. 6. Clean the pivot tube then apply lubricant to the exterior of the tube. 7. Installation procedure is reverse of the removal procedure.
HYDRAULIC FLUID DRAIN, FLUSH, AND REPLACE Tools 1/4, 7/16 combo wrench Container Expendable Hydraulic fluid Replaceable None Service Rating Line Minimum Certification LSA-RM or A&P Additional References KAI Matco user manual
DRAINING 1. Place suitable containers beneath each brake caliper to capture hydraulic fluid from each bleeder valve. 2. Open the bleeder valve on each brake caliper and allow fluid to drain.
FLUSHING / REPLACING 1. Install a clear hose on the top of the brake fluid reservoir and insert it in a container to catch fluid overflow. 2. Attach a pump style oil can filled with hydraulic fluid to the bleeder valve on the bottom of one of the brake calipers. Open the bleeder valve and pump the oil can until clean fluid flows in the clear tube at the top of the fluid reservoir. Close the bleeder valve and remove the oil can and hose. 3. Repeat the previous step on the other brake caliper. 4. Confirm that the brake peddle at each seat position for the left and right brake systems feel firm with no sponginess when pressed. Also confirm that there are no air bubbles visible in the translucent brake lines between the left and right seat rudder pedals. If there is any sponginess or presence of air bubbles repeat the flushing / replacing steps. 5. Use a syringe to slightly reduce the fluid level in the reservoir and reinstall the reservoir cap.
7-5
Rev. 2
BRAKE LINING REPLACEMENT
● NOTE: IT IS RECOMMENDED TO REPLACE ALL OF THE BRAKE LININGS ON BOTH SIDES EVEN IF ONLY ONE LINING REQUIRES REPLACEMENT.
Tools 7/16 socket Expendable Brake linings Safety wire Replaceable Brake disc Service Rating Line Minimum Certification LSA-RM or A&P Additional References KAI Matco user manual 1. Remove the 2 safety wired bolts and remove the stationary brake shoe. 2. Remove the brake housing from the brake plate (use care to not damage the aluminum brake line) 3. Remove the floating brake shoe. 4. Check that the brake disc is within wear limits. Replace if necessary. 5. Install new linings on the brake shoes per Matco instructions. 6. Install the floating brake shoe. 7. Install the brake housing on the brake plate. 8. Install the stationary brake shoe and safety wire the bolts. 9. Test for proper brake system operation. Check the hydraulic fluid level.
7-6
Rev. 5 CHAPTER 8 - ELECTRICAL SYSTEM
OVERVIEW ...... 8-2 Components ...... 8-2 Optional Lighting ...... 8-3 Optional Components ...... 8-3 SERVICE ...... 8-4 Supplies ...... 8-4 Tools ...... 8-4 Expendable ...... 8-4 Replaceable ...... 8-4 General ...... 8-5 Battery removal ...... 8-5 Installation ...... 8-5 Fuse replacement ...... 8-6 Pitch-trim servo replacement ...... 8-7 Electrical component replacement ...... 8-9 AV Control board replacement ...... 8-10 Wire repair ...... 8-11 Wire replacement ...... 8-11 Snap bushing replacement ...... 8-13 Service Schedule Procedures ...... 8-14 Battery terminal cleaning ...... 8-14 Battery recharge ...... 8-14 Terminal tab cleaning ...... 8-14
● NOTE: FOR A SCHEMATIC OF THE ELECTRICAL SYSTEM REFER TO THE POH OR GO TO THE DOWNLOADS PAGE AT WWW.VANSAIRCRAFT.COM
8-1
Rev. 5
OVERVIEW
▲ WARNING: THE RV-12 CONTROL BOARD IS NOT SERVICEABLE. SERIOUS RISK OF ELECTRIC SHOCK REMAINS AFTER THE POWER SUPPLY IS REMOVED.
The RV-12 electrical system is a 12 VDC, negative ground system. A 12 VDC sealed dry cell battery mounts on the forward side of the firewall. The generator operates only while the engine is running. The generator supplies power to the regulator, which serves the primary aircraft power and charges the battery. The primary aircraft power is a 30 amp fused circuit. Lights, servos, fans, avionics, fuel pump, and safety switches are all fused secondary circuits and part of the primary circuit. • NOTE: This maintenance manual is intended to be used in conjunction with the RV-12 Kit Assembly Instructions (KAI) when completing maintenance or repair processes.
COMPONENTS Quantity Part or Assembly Name Part Number or Reference 1 Battery ES PC680 12 Blade Fuse ATO/ATC ¼ “ blade style 1, 2, 3, 5, 7.5, 30 Amp rating. All fuse values of 3 amp and higher are required to have LED “blown fuse” indicators. 1 Stall Warning switch ES E22-50K 2 Fuselage pin switch ES E22-50K 1 Pitch-Trim servo ES-MSTS-T3-7A-2 2 Cooling Fan SW3DPS 1 12 VDC Supply AS212 2 Grip Switch PTT SWITCH & COVER 2 Intercom jacks (Headset) AV FC-JACK SET 2 Intercom jacks (MIC) AV FC-JACK SET 1 Master relay ES 24115 1 Instrument panel control board AV Control Board 12 16 Terminal Tab (wing-to-fuse) VA-262 1 OAT Sender Refer to Dynon Manual 2 EGT sender Refer to Dynon Manual 2 CHT sender Refer to Dynon Manual 1 Starter Refer to Rotax Manual 1 Regulator EA-F4120 or EA-F4122 1 Ignition A Refer to Rotax Manual 1 Ignition B Refer to Rotax Manual 1 Starter relay Refer to Rotax Manual
8-2
Rev. 5 OPTIONAL LIGHTING The lighting components include the wing tip strobe light, extension, landing light rib, landing light, lens backing strip, landing light lens, cooling shroud and red eyeball cockpit light. See Figure 20. The wing tip light mounts in the extension which attaches to the wing tip. The landing light is mounted to the landing light rib which is attached inside the wing skin. The eyeball light mounts to the rollover structure. Refer to the KAI for empennage component removal and installation.
Figure 20: Optional Wing Tip Lighting (cooling shroud & eyeball light not shown)
OPTIONAL COMPONENTS Quantity Part or Assembly Name Part Number or Reference 1 Lighting See shaded items below & Refer to KAI 1 Wing Tip NAV/Position/ LN-200-1 (green light shown) Strobe Light Set 2 Extension W-1222-L and W-1222-R 1 Lens Backing Strip W-1223E 1 Landing Light LL-200 1 Landing Light Lens LL DW 10 Lens Only Not Shown See shaded items below & Refer to KAI 1 Landing Light Rib W-1223B 1 Rect./Reg. Cooling Shroud F-00002 1 Red Eyeball Cockpit Light LC ECL-02
8-3
Rev. 5 SERVICE
▲WARNING: ALWAYS HAVE AN APPROPRIATE FIRE EXTINGUISHER READILY AVAILABLE. ▲WARNING: BEFORE PERFORMING ANY MAINTENANCE OR REPAIRS TURN THE MASTER SWITCH 'OFF' AND DISCONNECT THE NEGATIVE (-) BATTERY CABLE FROM THE BATTERY. ■ CAUTION: REPLACEMENT COMPONENTS, WIRE, TERMINALS, AND FUSES MUST BE OF THE SAME TYPE AND RATING AS THE ORIGINAL PARTS.
There are no serviceable electrical components. Replace malfunctioning or failed components. Electrical components that are omitted from the component list on page 8- 2 are not considered line maintenance.
SUPPLIES
TOOLS EXPENDABLE Socket: Baking soda/water ▪ 3/8 Wire terminals: ▪ 7/16 ▪ Splice ▪ 10 mm ▪ Spade (male/female) Battery charger ▪ Ring Scouring pad or equivalent Wire terminal crimping tool Wire cutter REPLACEABLE Multi-meter See component list on page 8-2. Razor knife Wire (gauge = original) Screwdriver Snap bushing (size = original) ▪ #2 Phillips ▪ #8 Phillips Needle nose pliers Fire extinguisher 4mm Allen wrench
8-4
Rev. 5 GENERAL
BATTERY REMOVAL
▲ WARNING: NEUTRALIZE BATTERY CORROSION WITH WATER/BAKING SODA MIX.
Tools 4 mm allen wrench, 3/8 socket Expendable None Replaceable Battery Service Rating Preventative Minimum Certification Owner and SPC, LSA-RM or A&P Additional References Odyssey owner manual
1. Remove the top cowl. (12-4) 2. Remove the negative (-) battery cable. 3. Remove the positive (+) battery cable. 4. Remove the battery channel. 5. Lift the battery to remove.
INSTALLATION 1. Installation procedure is reverse of the removal procedure.
8-5
Rev. 5
FUSE REPLACEMENT
■ CAUTION: BLOWN FUSES MUST BE REPLACED ONLY WITH FUSES OF THE SAME TYPE AND RATING AS SPECIFIED BY THE MANUFACTURER. ■ CAUTION: THE MASTER SWITCH MUST BE IN THE ‘OFF’ POSITION BEFORE REPLACING ANY FUSE. ● NOTE: REPLACEMENT FUSES FOR ANY CIRCUIT IN WHICH A 5 AMP FUSE OR LARGER IS SPECIFIED MUST BE OF THE TYPE THAT ILLUMINATE WHEN BLOWN.
Good Fuse Blown Fuse
1. Remove the suspected blown fuse. 2. Perform visual inspection and/or use multi-meter to test fuse. 3. Insert new fuse with proper SkyView/G3X rating as shown in Figure 21. 4. A recurring blown fuse indicates excessive current draw from the corresponding circuit of the electrical system. See Chapter 18.
D-180
Figure 21: Fuse panel
8-6
Rev. 5
PITCH-TRIM SERVO REPLACEMENT Tools 3/8, 7/16 socket 3/16 combo wrench #2 Phillips screwdriver Wire cutter Terminal crimping tool Needle nose pliers Expendable Wire terminals Replaceable Pitch-Trim servo Service Rating Line Minimum Certification LSA-RM, or A&P Additional References KAI
1. Disconnect the negative (-) battery cable. 2. Remove the upper and lower tailcone fairing. (3-4) 3. Label, then disconnect the pitch-trim servo wire terminal connections. Remove the cushioned clamp and free the tailcone wire from the trim/servo assembly. 4. Make note of the hardware configuration. 5. Disconnect the trim/servo assembly from the AST assembly by removing the bolt, washers (3) and nut as shown in Figure 22. 6. Disconnect the trim/servo assembly from the tailcone by removing the cotter pin, bolt, bushings (2), washer and nut. Remove the trim/servo assembly from the aircraft as shown in Figure 22.
8-7
Rev. 5
Figure 22: Trim/Servo assembly removal
7. Remove the pitch-trim servo attach screws (6), washers (6), nuts (6), and doublers (2) as shown in Figure 23. 8. Unscrew the pitch-trim servo from the pushrod assembly. Remove the jam nut from the pitch-trim servo shaft. 9. Clip the wire terminals off of the old servo and remove the snap bushing. Slide the snap bushing onto the wires of the new servo.
Figure 23: Pitch-trim servo removal 1. Install new terminals on the three colored wires of the servo.
8-8
Rev. 5 2. Thread the jam nut onto the new pitch-trim servo shaft until it contacts the pitch trim servo shaft housing. Thread the pitch-trim servo shaft onto the clevis rod end on the pushrod assembly until it contacts the jam nut. Back the pitch-trim servo off two full turns. Tighten the jam nut against the pushrod assembly.
INSTALLATION 1. Install the servo on the servo tray by reversing the process done in step 7. 2. Install the trim/servo assembly by reversing the process used in step 6. 3. Connect the three colored pitch trim servo wires with previously installed terminals to the matching colored wires on the pitch trim CONTROL CABLE. 4. Temporarily connect the two white wires on the pitch trim servo to the remaining two wires on the pitch trim control cable. 5. Switch on the master switch and verify that when the pitch trim is activated in the nose down direction, the antiservo tab assembly moves up. If the AST moves in the wrong direction, swap the two white wire positions and recheck. 6. When the AST movement has been verified as correct, install appropriate connectors on each wire for connecting to the pitch trim control cable.
ELECTRICAL COMPONENT REPLACEMENT (EXCLUDING THE PANEL CIRCUIT BOARD)
▲WARNING: BEFORE PERFORMING ANY MAINTENANCE OR REPAIRS TURN THE MASTER SWITCH 'OFF' AND DISCONNECT THE NEGATIVE (-) BATTERY CABLE FROM THE BATTERY. ■ CAUTION: REPLACEMENT COMPONENTS, WIRE, TERMINALS, AND FUSES MUST BE OF THE SAME TYPE AND RATING AS THE ORIGINAL PARTS.
Tools 3/8, 7/16 socket #2 Phillips screwdriver Wire cutter Terminal crimping tool Needle nose pliers Expendable Wire terminals Replaceable See component list. (8-2) Service Rating Line Minimum Certification LSA-RM, or A&P Additional References KAI 1. Disconnect negative (-) ground wire. 2. Remove the applicable access covers to expose the failed component (3-4) 3. Label the wires. Disconnect the wire(s) from the failed component. 4. Make note of the hardware configuration. 5. Disconnect the mechanical connection, if applicable. 6. Remove the hardware that secures the component and remove the component. 7. Install a new component, new gaskets (if applicable), and hardware of the same
8-9
Rev. 5 type. 8. Re-attach applicable electrical and mechanical connections. 9. Reconnect the negative (-) battery cable.
AV CONTROL BOARD REPLACEMENT Tools #2 Phillips screwdriver small flat blade screwdriver Expendable None Replaceable AV Control Board Service Rating Line Minimum Certification LSA-RM,A&P or Approved Owner Additional References KAI
1. Disconnect negative (-) battery cable. 2. Remove the panel cover. (3-4) 3. Discharge the circuit board. With the master switch 'ON', press the stall warning vane until the tone fades off. If wings are removed, ground the stall warning terminal tab at the fuselage side cover as shown in Figure 24. 4. Verify all plugs and connectors and their connected locations are properly labeled. 5. Disconnect the control board connections. 6. Remove the control board attachment hardware. 7. Remove the control board. 8. Install the new control board and hardware of the same type. 9. Re-attach all plugs and connectors. 10. Reconnect the negative ground wire to the battery. 11. Test for correct operation of all electrical circuits.
Figure 24: Stall Warning Ground
8-10
Rev. 5
WIRE REPAIR Tools Wire cutter Wire terminal crimper Multi-meter Expendable Wire terminals Replaceable Wire Service Rating Line Minimum Certification LSA-RM, or A&P Additional References ASTM F39 F2639
■ CAUTION: THE REPLACEMENT WIRE SIZE AND TYPE MUST BE EQUAL TO THE ORIGINAL.
1. Remove the entire damaged section of the wire. 2. Fix the issue that caused damage to the original wire (sharp edge, chaffing, heat, etc). 3. Route the new length of wire along the same path as the original wire. 4. Use aircraft grade wire terminals to connect the new wire in place of the original wire. 5. Test the continuity of the wire to ensure a complete connection. 6. Test the operation of the electrical system.
WIRE REPLACEMENT Tools Wire cutter Wire terminal crimper Needle nose pliers Multi-meter Expendable Wire terminals Replaceable Wire Service Rating Line Minimum Certification LSA-RM or A&P Additional References ASTM F39 F2639
■ CAUTION: THE REPLACEMENT WIRE SIZE AND TYPE MUST BE EQUAL TO THE ORIGINAL.
8-11
Rev. 5
1. Bypass the existing wire with a new wire of equal length. 2. Install new terminals on the new wire that are the same type as those on the existing wire. 3. Connect the new wire terminals to the terminals that are connected by the existing wire. 4. Check the continuity of the replacement wire. 5. Test the operation of the component that is connected by the replacement wire and test the operation of the entire electrical system.
8-12
Rev. 5
SNAP BUSHING REPLACEMENT Tools Razor knife Expendable None Replaceable Snap bushing Service Rating Line Minimum Certification LSA-RM, or A&P Additional References KAI 1. Extract the failed snap bushing by compressing the two locking tabs and pushing it out of the mounting hole.
2. Cut the new snap bushing as shown in Figure 25. The snap bushing should be of the same size and type as the original.
Figure 25: Snap Bushing 3. Flex open the bushing enough to insert the routed elements. 4. Snap the bushing into the corresponding hole.
8-13
Rev. 5 SERVICE SCHEDULE PROCEDURES
BATTERY TERMINAL CLEANING ▲ WARNING: NEUTRALIZE BATTERY CORROSION WITH WATER/BAKING SODA MIX.
Tools Scouring pad Expendable Baking soda/water Replaceable None Service Rating Preventative Minimum Certification Owner and SPC, LSA-RM, or A&P Additional References Odyssey owners manual 1. Remove the battery from the aircraft. (8-5) 2. Clean and score both battery and wire terminals with a scouring pad or equivalent. 3. Re-install the battery.
BATTERY RECHARGE Tools Battery charger Expendable None Replaceable None Service Rating Preventative Minimum Certification Owner and SPC, LSA-RM, or A&P Additional References Odyssey owner manual Battery charger owner manual 1. Remove the battery from the aircraft. (8-5) 2. Connect the battery charger per the battery charger manufacturer instructions. 3. Charge the battery per the battery manufacturer instructions.
TERMINAL TAB CLEANING Tools Scouring pad Expendable None Replaceable None Service Rating Preventative Minimum Certification Owner and SPC, LSA-RM, or A&P Additional References KAI 1. Remove the wings from the fuselage. (5-13) 2. Remove dirt, carbon and corrosion from all of the terminal tabs on both sides of the fuse and both wings using a scouring pad.
8-14
Rev. 7 CHAPTER 9 - INSTRUMENTS & AVIONICS
OVERVIEW ...... 9-2 Components ...... 9-2 Optional Components ...... 9-3 PITOT & STATIC...... 9-3 Components ...... 9-3 SERVICE ...... 9-4 Supplies ...... 9-4 Tools ...... 9-4 Expendable ...... 9-4 Replaceable ...... 9-4 General ...... 9-5 Component replacement ...... 9-5 Light replacement ...... 9-5 Service Schedule Procedures ...... 9-6 Software updates ...... 9-6
9-1
Rev. 7 ___ OVERVIEW The Dynon D-180, Dynon SkyView or Garmin G3X EFIS (Electronic Flight Information System) / EMS (Engine Monitoring System) replaces the traditional mechanical flight information and engine monitoring instruments. For removal, installation, inspection, or servicing of the avionics components refer to the manufacturer user manuals. The pitot and static systems provide static and dynamic pressure sources for flight data calculations. The static system ports are located on each side of the tailcone. A flexible plastic tube from the right static port crosses the tailcone to a plastic tee and joins the flexible plastic tube from the left port. From the tee, a flexible plastic tube routes to the floor, then forward within the center tunnel to the air data computer located behind the instrument panel with the D-180 and in the aft fuselage with the Skyview and G3X. The pitot port is an aluminum tube located at the tip of the spinner cone that extends aft to an adapter block mounted to the engine. A flexible plastic tube continues aft from the adapter block to the air data computer.
• NOTE: This maintenance manual is intended to be used in conjunction with the RV-12 Kit Assembly Instructions (KAI) when completing maintenance or repair processes.
COMPONENTS Quantity Part or Assembly Name Part Number or Reference 1 Dynon D-180 or Skyview See Dynon Manual 1 Dynon EDC-D10A See Dynon Manual 1 Garmin G3X See Garmin Manual 1 Garmin GPS Map 369 See Garmin Manual 1 Garmin GTX 327 or GTX 23 ES or SV- See Garmin Manual or XPNDR-26X Dynon manual 1 Garmin SL-40, GTR-200 or GTR-225 See Garmin Manual 1 Garmin GA26C See Garmin Manual 1 Garmin GXM30A or GA26XM See Garmin Manual 1 Transponder Antenna AV CI-101C 1 Emergency Locator Transmitter AV ME406 1 ELT Remote 453-0023 or E-04.5 1 ELT Antenna 110-773 or E-04.8 1 VHF Comm Antenna AV AV-17 1 Stereo Intercom AV FC-403 2 Static Port RIVET SD-42-BSLF 1 Plastic tee 125 X 125 X 125 TEE 1 Pitot block FF-1201, UHMW 1 Pitot tube FF-1202, AT6-058X5/16 1 Pitot line tubing FF-1216 1 Static line tubing PT 1/4 OD POLYPROP. TUBE
9-2
Rev. 7
OPTIONAL COMPONENTS 2 Autopilot Servo See Dynon or Garmin Manual 1 Dynon AP-74 Autopilot Interface Module IF DYNON AP AP74V-12 See Dynon Manual 1 SV-AP-PANEL See Dynon Manual 1 SV-KNOB-PANEL See Dynon Manual 1 Garmin GMC 305 Autopilot Controller See Garmin Manual 1 Landing light See Aero LED Manual 2 Navigation / Strobe light See Aero LED Manual 1 Cockpit light LC ELC-01 1 D-180 or D1000 or D1000T or G3X Dual See Dynon or Garmin Manual EFIS / EMS 1 AOA indicator system See Dynon or Garmin Manual
PITOT, STATIC & AOA
9-3
Rev. 7
COMPONENTS Quantity Part or Assembly Name Part Number or Reference 2 Static Source Rivet SD-42-BSLF 1 Plastic Tee 125 X 125 X 125 TEE 1 Pitot Block FF-1201, UHMW 1 Pitot Tube FF-1202, AT6-058X5/16
SERVICE ▲WARNING: ALWAYS HAVE AN APPROPRIATE FIRE EXTINGUISHER READILY AVAILABLE. ▲WARNING: BEFORE PERFORMING ANY MAINTENANCE OR REPAIRS TURN THE MASTER SWITCH 'OFF' AND DISCONNECT THE NEGATIVE (-) BATTERY CABLE FROM THE BATTERY. ■ CAUTION: REPLACEMENT COMPONENTS, WIRE, TERMINALS, AND FUSES MUST BE OF THE SAME TYPE AND RATING AS THE ORIGINAL PARTS.
Software updates are often available online for the Dynon D-180, Skyview, Garmin GPS, and Garmin G3X. The avionics components are not serviceable by the consumer unless otherwise noted in the manufacturer user manuals. A manufacturer authorized repair facility will perform diagnosis and service to the avionics components. The Cockpit, Nav/Strobe and Landing lights have no user serviceable parts. Check the supply voltage and circuit connections. Replace the inoperable light if necessary.
SUPPLIES
TOOLS EXPENDABLE Wire cutter Wire terminals Wire terminal crimper Plastic Tie Wraps Needle nose pliers 3/8” combination wrench REPLACEABLE 5/64” allen wrench Razor Knife See component list on page 9-2. Screwdrivers ▪ #2 Phillips ▪ Small flat blade Computer with internet Unit connection cable
9-4
Rev. 7 GENERAL
COMPONENT REPLACEMENT See 9-2 and 9-3.
COMPONENT REMOVAL BY CUSTOMER Using the KAI as a guide, customers are authorized to remove a screen or any electrical component that is to be sent in for service.
PITOT AND STATIC SYSTEM COMPONENT REPLACEMENT Tools Razor Knife Expendable Plastic tie wraps Replaceable Connector Tubing Service Rating Line Minimum Certification LSA-RM or A&P Additional References KAI
REMOVAL 1. Make note of routing, location and orientation of the component to replace. 2. Remove the failing component. INSTALLATION 1. Install a new component of equivalent properties and secure with plastic tie wraps. 2. Complete the pitot /static check as outlined in the RV-12 production acceptance test document.
LIGHT REPLACEMENT ▲WARNING: BEFORE PERFORMING ANY MAINTENANCE OR REPAIRS TURN THE MASTER SWITCH 'OFF' AND DISCONNECT THE NEGATIVE (-) BATTERY CABLE FROM THE BATTERY.
Tools Wire cutter Wire terminal crimper Needle nose pliers #2 Phillips screwdriver Expendable Wire terminals Replaceable Light Module Service Rating Preventative Minimum Certification Owner and SPC, LSA-RM or A&P Additional References KAI
9-5
Rev. 7
REMOVAL 1. Remove the light and fastening hardware; Landing light: screws (6), bolts (2) Navigation light: allen screw (1) 2. Label the wires that will be disconnected. 3. Unplug the wire terminals nearest to the light.
INSTALLATION 1. Install mating wire terminals on the replacement light. 2. Plug the light into the electrical system. 3. Install the new light and hardware.
SERVICE SCHEDULE PROCEDURES NOTE: THERE IS NO SCHEDULED MAINTENANCE OR SERVICE ON ANY OF THE AVIONICS OR OPTIONAL EQUIPMENT OTHER THAN THE PERIODIC REPLACEMENT OF THE ELT UNIT BATTERY. REFER TO THE ELT OWNERS MANUAL FOR THIS PROCEDURE. PERIODIC CHECKS SHOULD BE MADE AT A MINIMUM OF EACH CONDITION INSPECTION TO DETERMINE IF ANY SOFTWARE UPDATES HAVE BEEN ISSUED FOR THE EFIS/EMS OR GPS.
SOFTWARE UPDATES Tools Computer with internet access and Unit connection cable Expendable None Replaceable None Service Rating Preventative Minimum Certification Owner and SPC, LSA-RM or A&P Additional References F39
Refer to the applicable user manual for the instructions and website address.
Firmware updates and Read me files can be found at: http://www.vansaircraft.com/public/downloads.htm
9-6
Rev. 1 CHAPTER 10 - UTILITY SYSTEMS
OVERVIEW ...... 10-2 HEAT ...... 10-2 Components ...... 10-3 VENTILATION ...... 10-3 Components ...... 10-4 SERVICE ...... 10-4 Supplies ...... 10-4 Tools ...... 10-4 Replaceable ...... 10-4 Expendable ...... 10-4 General ...... 10-5 Vent door repair ...... 10-5 Service Schedule Procedures ...... 10-5 Push/pull cable lubrication ...... 10-5
10-1
Rev. 1
OVERVIEW The aircraft utility systems are the systems that are not critical to flight. The heat system enables the occupants to control the cockpit temperature with a push/pull cable. Hot air diverted from the heat exchangers provides cockpit heat. Cabin ventilation air can be controlled with either of the two vents, one on each side of the fuselage.
• NOTE: This maintenance manual is intended to be used in conjunction with the RV-12 Kit Assembly Instructions (KAI) when completing maintenance or repair processes.
HEAT
Air that passes through the engine coolant heat exchanger is heated. The heated air continues into the cooler box. A push / pull cable controls a door in the cooler box that diverts the heated air into, or away from the cockpit.
10-2
Rev. 1 COMPONENTS Quantity Part or Assembly Name Part Number or Reference 1 Cooler box FF-1204 1 Cooler box door FF-1205 1 Cooler box bracket FF-1205BC 1 Cooler box hinge FF-1206 1 Push / Pull Cable CT A-740
VENTILATION
A hand-operated vent on each side of the cockpit provides cockpit ventilation. Each vent is a tip-out door installed on each fuselage side skin.
10-3
Rev. 1 COMPONENTS Quantity Part or Assembly Name Part Number or Reference 2 Vent brackets F-1086 2 Vent doubler F-1096 Vent door sub-assembly See shaded items below 2 Vent slide F-1087 2 Vent door doubler F-1092 2 Vent door F-1093
SERVICE The heating system does not require regular maintenance. If the push / pull cable operation is not smooth at the time of the annual condition inspection, lubricate the moving parts. If the heated air temperature is noticeably cooler than previous uses, see troubleshooting. The pre-flight and annual condition inspections are necessary to ensure all of the components remain in good condition. No maintenance is required on either of the fresh-air vents. A damaged vent is replaceable provided the fuselage skin is undamaged.
SUPPLIES
TOOLS REPLACEABLE
Razor Knife Connector ( = to original) #30 drill bit Tubing ( = to original) Blind rivet tool Vent door sub-assembly Combination wrench: Vent brackets ▪ 1/4 Screwdriver: ▪ #2 Phillips
EXPENDABLE Spray lubricant Plastic tie wraps LP4-3 rivets
10-4
Rev. 1 GENERAL
VENT DOOR REPAIR Tools #30 drill bit Blind rivet tool 1/4 combo wrench #2 Phillips screwdriver Expendable LP4-3 rivets (4) Screw Plastic washers (2) Metal washer Nut Replaceable Vent door sub-assembly Vent brackets (2) Service Rating Line Minimum Certification LSA-RM or A&P Additional References KAI
1. Remove the existing vent brackets and vent door sub-assembly by drilling out the rivets (4). 2. Rivet the new vent brackets to the vent doorframe. 3. Install a new vent door sub-assembly to the vent brackets using new hardware; screw, plastic washers (2), metal washer, and nut.
SERVICE SCHEDULE PROCEDURES
PUSH/PULL CABLE LUBRICATION - NONE
10-5
Rev. 1
THIS PAGE INTENTIONALLY LEFT BLANK
10-6
Rev. 6 CHAPTER 11 - PROPELLER
PROPELLERPROPELLERPROPE
LLER
OVERVIEW ...... 11-2 Components ...... 11-2 SERVICE ...... 11-2 Supplies ...... 11-2 Tools ...... 11-2 Expendable ...... 11-2 Replaceable ...... 11-2 Spinner and Pitot Tube ...... 11-3 Prop & Hub ...... 11-3
11-1
Rev.6
OVERVIEW The RV-12 has a ground adjustable Sensenich propeller. For instructions to adjust the propeller pitch, refer to the user manual provided with the propeller. The current propeller manuals and/or specifications take precedence over referenced information in this manual. Current revisions to products or specifications made by the propeller manufacturer will not be reflected in this manual.
• NOTE: This maintenance manual is intended to be used in conjunction with the RV-12 Kit Assembly Instructions (KAI) when completing maintenance or repair processes.
COMPONENTS Quantity Part or Assembly Name Part Number or Reference 2 Propeller blade 2A0R5R70EN Blade 1 Propeller hub Hub 1 Spinner cone S-1201 1 Optional Propeller Unit, 3 Blade 3Y0R5 C70MY 1 Optional Spinner Cone, 3 Blade S-01214
SERVICE Brief instructions, referenced from the propeller manual, about caring for the prop and hub are included below. For complete information, refer directly to the propeller manual. The spinner cone is constructed with a bushing for the pitot tube. It has no scheduled maintenance requirement other than regular inspection and replacement of the bushing if excessive wear is detected.
SUPPLIES
TOOLS EXPENDABLE
7/16 diam. wood dowel Notebook paper Small hammer Screwdriver: ▪ #2 Phillips REPLACEABLE
Spinner cone Pitot tube bushing
11-2
Rev.6
SPINNER AND PITOT TUBE
Inspect the Pitot tube and bushing for excessive wear using a clearance gauge. Make the clearance gauge by cutting a ¾ inch X 4 inch paper strip from common note book paper (typical thickness is about .003 inch). Make a mark on the strip ¾ inch from one end. Lay the paper strip lengthwise on the portion of the pitot tube that protrudes out of the spinner with the marked end positioned nearest to the spinner. Wrap the paper strip tightly around the radius of the pitot tube and attempt to insert it between the pitot tube and the bushing. If the paper strip can be inserted to the marked ¾ inch depth further inspection is needed. Remove the spinner and inspect the portion of the pitot tube that turns within the bushing for wear damage. If any is present the pitot tube and the bushing should be replaced. To replace them see Section 47 of the KAI. If no wear damage is present on the pitot tube, just the bushing should be replaced. Remove the worn bushing by driving it out from the aft side of the spinner using a 7/16 in. diameter dowel. Install the new bushing per Section 47 of the KAI.
PROP & HUB
●NOTE: THERE IS NO SPECIFIED SERVICE LIFE FOR THE PROPELLER. HOWEVER IT IS TO BE REMOVED FROM SERVICE WHEN IT NO LONGER MEETS THE CONTINUED AIRWORTHINESS REQUIREMENTS SPECIFIED BY THE MANUFACTURER.
The following will aid in the safe operation, longevity and appearance of the propeller. • Do not spin your propeller above the Propeller RPM Limits specified by the manufacturer • Check the hub clamping bolt torque after the first 5 hours and at each condition inspection. Always check in the tightening direction. • Before each flight carefully Inspect the propeller blades and hub for looseness, any signs of damage, excessive wear or any other condition that would make the propeller unsafe to operate. • When the propeller is not in use position it horizontally. If it is exposed to weather cover it with a weatherproof cover. • Do not use the propeller as a tow-bar to move your aircraft. • Apply a good quality automotive paste wax to the blades at least once a year. Avoid liquid waxes. • Avoid running-up in areas containing loose stones and gravel. • Loss of surface finish from the leading edge is considered normal wear and is dependent upon the amount of operation in rain and grit.
11-3
Rev.6
• Immediately following an impact of any kind remove the propeller from service until it has been inspected and passed by qualified personnel. • A dynamic propeller balance should be considered if any of the following events occur (If balance weights are needed, drill holes in the appropriate locations on the rear spinner bulkhead and install the weights there.): • Evidence of rough operation or excessive vibrations. • Mass of propeller assembly is changed. • Propeller is removed from engine. • Removal is characterized by the removal of the entire hub assembly from the prop shaft. • If the aft hub half remains on the prop shaft, a dynamic propeller balance should not be necessary. Removed components must be reinstalled exactly as removed, otherwise a dynamic propeller balance should be performed.
NOTE: The following items are of concern without a balanced propeller. Please note this list is not exhaustive. • Decreased AHRS accuracy and failure of EFIS components • Fatigue of airframe components • Pitot tube failure
• If the propeller shows any of the following signs of damage it must either be repaired (if possible) or retired from service: ▪ Cracks in the metal hub or bolts ▪ Loose metal leading edge ▪ A crack across the blade ▪ A long or deep crack along the blade length ▪ Any portion of composite material missing ▪ Obvious damage or wear beyond economical repair
11-4 Rev.5
CHAPTER 12 - FIREWALL FORWARD
OVERVIEW ...... 12-2 Components ...... 12-2 Engine ...... 12-3 Rotax 912ULS ...... 12-3 Spark Plugs ...... 12-3 Ignition ...... 12-3 SERVICE ...... 12-3 Supplies ...... 12-4 Tools ...... 12-4 Expendable ...... 12-4 Replaceable ...... 12-4 General ...... 12-4 Cowling removal ...... 12-4 Spark plug replacement ...... 12-5 Oil filter replacement ...... 12-5 Engine oil level check ...... 12-6 Engine coolant level check ...... 12-6 Air filter removal ...... 12-7 Installation ...... 12-7 Carburetor Syncronization ...... 12-7 Throttle Cable Hookup ...... 12-10 Vacuum Gauge Hookup ...... 12-10 Off Idle Setting ...... 12-12 Idle Speed Adjustment ...... 12-12 Verify Functionality of Throttle Return Spring ...... 12-14 Throttle Spring Replacement ...... 12-15 Service Schedule Procedures ...... 12-16 Cowl hinge pin lubrication ...... 12-16 Oil Hose Replacement ...... 12-16 Cooling Hose Replacement ...... 12-17 Manifold Pressure Hose Replacement ...... 12-17 Cylinder, Piston , and Valve Assembly Replacement ...... 12-18 Engine Replacement ...... 12-19
12-1 Rev.5
.OVERVIEW Engine information is taken from Rotax documentation. For complete engine information refer to the Rotax engine documentation. Note: Rotax is the primary authority for specifying the level of certification required by an individual performing maintenance or repair on a Rotax 912 engine. Refer to the Rotax documentation to determine the qualifications or training required for any maintenance or repair action. The top and bottom engine cowling are a formed composite of fiberglass cloth and epoxy-resin. The cowl is attached using screws and segments of piano hinge. Hinge also attaches the top and bottom cowl halves together. Adhesive heat shielding protects the inner surface of the cowl. The throttle and choke are the only engine controls. Air duct and engine cooling shrouds of similar construction provide cooling to the cylinders and heat exchangers.
• NOTE: This maintenance manual is intended to be used in conjunction with the RV-12 Kit Assembly Instructions (KAI) when completing maintenance or repair processes.
COMPONENTS Quantity Part or Assembly Name Part Number or Reference 1 Rotax 912ULS Refer to Rotax documentation & See Figure 26. 1 Engine mount WD-1220-PC 4 Vibration isolator EA 22002-15 4 Engine Mount Bushing Aluminum tube .376 X .525 X 1.9 Engine controls See shaded items below 1 Throttle cable CT DUAL THROTTLE CABLE 1 Choke cable CT DUAL CHOKE CABLE Cowling See shaded items below 1 Top cowl Cowl, 12 Top 1 Bottom cowl Cowl, 12 Bottom 1 Air duct Cowl, 12 Cooling Duct 1 Upper cowl hinge F-1201J 1 Upper cowl hinge F-1201K 2 Mid cowl hinge F-12116 2 Lwr cowl hinge F-12117 2 Cowl attach plate F-12118 1 Cowl shield EA EXHST/COWL SHIELD
12-2
Rev.5
ENGINE
Figure 26: Rotax 912ULS
Current engine product manuals and/or specifications take precedence over any associated information referenced in this manual for convenience. This manual will not reflect current revisions to products or specifications made by the engine manufacturer. Refer to the engine manufacturer's operators manual for specifications.
SPARK PLUGS Type: NGK DCPR8E Socket: 16mm Electrode Gap: See Rotax Documentation
IGNITION Dual Breakerless Capacitor Discharge Firing Order: 1 - 4 - 2 - 3
SERVICE Refer to the engine manual for full engine service details. The cowling does not require regular maintenance. The cowl attach hinge pins may be lubricated with a dry lubricant to ease removal and installation.
12-3
Rev.5 SUPPLIES
TOOLS EXPENDABLE
Socket: Spray lubricant ▪ 3/8 Engine coolant ▪ 5/16 Engine oil ▪ 9/16 Dry lubricant ▪ 16 mm (spark plug type) Oil filter Combination wrench: Safety wire ▪ 3/8 Cotter pins ▪ 9/16 Screwdriver: ▪ #2 Phillips REPLACEABLE Spark plug gap tool (wire type) Hinge pins Needle nose pliers Spark Plugs Vibration isolator Air filter Push/Pull cable
GENERAL
COWLING REMOVAL Tools #2 Phillips screwdriver Expendable None Replaceable Hinge pins Service Rating Preventative Minimum Certification Owner and SPC, LSA-RM or A&P Additional References KAI 1. Remove the screws (2) in the F-1240B Cover Plate located at the top rear of the cowling to access the cowl attach hinge pins. 2. Top Cowl: Remove the top cowl fwd. attach screws (6), side pin anchor screws (2), hinge pins (4) and the top cowl. 3. Bottom Cowl: Remove the bottom cowl attach screws (12) located on the bottom of the cowl, the oil cooler attach screws (2) located at the top of the oil cooler, the hinge pins (4) and the bottom cowl. Note: The oil cooler will remain attached to the airplane, hanging in place by its associated oil hoses.
INSTALLATION 1. Installation procedure is reverse of the removal procedure. Note: As the lower cowl is lifted into place maneuver the oil cooler so that its lower notches drop onto the Cowl 12 Guides. The cooler should then self align to allow for installing the attach screws.
12-4 Rev.5
SPARK PLUG REPLACEMENT OR RE-INSTALLATION Tools 16mm socket Spark plug gap tool Expendable Heat conduction compound Replaceable Hinge pins Spark Plugs - if serviceable Service Rating Preventative Minimum Certification LSA-RM with Rotax Service certification or A&P with Rotax Service Certification. Additional References Rotax 912 Line Maintenance manual 1. Refer to the Rotax manual.
OIL FILTER REPLACEMENT OR RE-INSTALLATION Tools Oil filter wrench Expendable Oil Filter Replaceable None Service Rating Preventative Minimum Certification Owner and SPC, LSA-RM or A&P Additional References Rotax 912 Line Maintenance manual
ENGINE OIL LEVEL CHECK ▲ WARNING: BEFORE PERFORMING ANY INSPECTION OR SERVICE, ALLOW THE ENGINE COMPONENTS TO COOL. ▲ WARNING: TURN OFF MASTER POWER AND BOTH IGNITION SWITCHES. DISCONNECT THE NEGATIVE (-) GROUND WIRE TO THE BATTERY. ● NOTE: FOR ENGINE OIL CAPACITY SEE ROTAX 912 OPERATORS MANUAL.
Tools None Expendable None Replaceable None Service Rating Preventative Minimum Certification Owner and SPC, LSA-RM or A&P Additional References Rotax 912 Operator Manual
1. Remove the oil tank cap. 2. Transfer oil from the crankcase to the oil tank by turning the propeller several times by hand in the direction of normal engine rotation. Transfer is complete when gurgling sounds come from the oil tank.
12-5
Rev.5
■ CAUTION: FOR LONG FLIGHTS REPLENISH OIL TO THE ‘MAX.’ MARK ON THE DIPSTICK. ● NOTE: THE QUANTITY DIFFERENCE BETWEEN ‘MAX.’ AND ‘MIN.’ MARKS ON OIL DIPSTICK IS 0.45L (0.5 QUART). 3. Oil level must be between the ‘Max’ and ‘Min’ marks on the dipstick.
ENGINE COOLANT LEVEL CHECK ▲ WARNING: DO NOT REMOVE THE RADIATOR CAP FROM A HOT COOLING SYSTEM. SCALDING COOLANT WILL SPRAY. ▲ WARNING: BEFORE PERFORMING ANY INSPECTION OR SERVICE, ALLOW THE ENGINE COMPONENTS TO COOL.
Tools None Expendable Engine coolant Replaceable None Service Rating Preventative Minimum Certification Owner and SPC, LSA-RM or A&P Additional References Rotax 912 Operator Manual 1. Place a rag over the expansion tank cap. 2. Loosen cap to the first detent then step back for a few seconds. 3. Remove the expansion tank cap. 4. The expansion tank must be full of coolant. 5. Replace the cap. 6. The coolant level in the overflow bottle must be between the ‘Max’ and ‘Min’ marks.
AIR FILTER REMOVAL Tools 5/16” Socket Expendable None Replaceable Air filter Service Rating Line Minimum Certification LSA-RM or A&P Additional References Rotax 912 Line Maintenance manual 1. Loosen the air filter clamp. 2. Remove the air filter. INSTALLATION 1. Installation procedure is reverse of the removal procedure.
12-6
Rev.5
CARBURETOR SYNCHRONIZATION Tools 1 - Vacuum gauge set 1 - .050 Allen wrench 2 - 3/8 in. combination wrench 2 - 10 mm combination wrench 1 - medium flat blade screwdriver 1 - #2 Phillips screwdriver Expendable None Replaceable None Service Rating Line Minimum Certification LSA-RM with Rotax Service certification or A&P with Rotax Service certification Additional References Rotax Maintenance Manual
● NOTE: THIS PROCEDURE IS WRITTEN FOR A SINGLE CARBURETOR. ADJUST BOTH CARBURETORS SIMULTANEOUSLY.
THE CARBURETOR SYNCHRONIZATION PROCEDURE IN THE ROTAX MAINTENANCE MANUAL SHOULD BE CONSIDERED THE PRIMARY INFORMATION SOURCE FOR ANY AND ALL ENGINE MAINTENANCE. THE FOLLOWING STEPS LIST THE SIMPLEST PROCESS VAN'S AIRCRAFT HAS FOUND TO ACHIEVE THE SMOOTHEST RUNNING ENGINE POSSIBLE.
MECHANICAL SYNCHRONIZATION
12-7
Rev.5
Figure 27: Carburetor Overview (Right Carburetor Shown)
● NOTE: FOR STEP 1 THROUGH STEP 8 REFER TO FIGURES 27 AND 28.
1. Remove the throttle cable locking hardware from the throttle arm. 2. Release the full throttle return spring from its attachment on the throttle arm. 3. Return the throttle arm to its idle position limit of travel by hand, there should be no resistance during this procedure. 4. Turn the idle speed adjustment screw counterclockwise until it is no longer contacting the idle stop. 5. Hold the throttle arm lightly against its idle position limit of travel. Insert a .1mm (.004in) feeler gauge between the idle speed adjustment screw and the idle stop. Gently turn the idle speed adjustment screw clockwise until contact is made with the .1mm feeler gauge. 6. From this point turn the idle speed adjustment screw clockwise 1.5 turns. 7. Gently turn the mixture screw completely closed (clockwise) and then reopen by
12-8
Rev.5
1.5 turns counter-clockwise. Note this step cannot be done without removing the carburetor from the manifold. With a new engine initially assume it is properly set at the factory. 8. Hook-up the full throttle return spring, previously disconnected, back to its original position on the throttle arm.
Figure 28: Mixture Screw
12-9
Rev.5
HOOKING THE THROTTLE CABLE LEAD TO THE THROTTLE ARM
9. Pull the throttle handle away from the instrument panel the distance prescribed in Figure 29, then tighten the friction adjustment. This is the idle position.
Figure 29: Throttle Handle Idle Position
10. Actuate the throttle arm so that the idle stop is lightly contacting the idle speed adjustment screw. While holding tension on the throttle cable lead, tighten the throttle cable locking hardware to 8-10 in-pounds. See Figure 27. You must insure that the idle speed adjustment screw is resting on the idle stop and that there is no clearance between the two when the throttle handle is in the idle position. 11. Loosen the friction adjustment. See Figure 29.
VACUUM GAUGE HOOKUP
● NOTE: THERE ARE THREE WAYS TO CONNECT A VACUUM GAUGE AS DESCRIBED IN THE ROTAX MAINTENANCE MANUAL. THE FOLLOWING STEP ASSUMES THE USE OF OPTION 3.
12. Unhook the balance tube at the right side end by removing the securing clamp from the push-on connection. Using the push-on connection and the hose elbows on the intake manifolds, install rubber hoses leading to a dual vacuum gauge. See Figure 30.
12-10
Rev.5
Figure 30: Vacuum Gauge Hookup
13. Secure the aircraft to the ground using chocks, ropes etc.
▲ WARNING: SECURE AND OBSERVE THE PROPELLER ZONE DURING ENGINE OPERATION!
14. Start the engine and warm it up until normal operating temperatures are achieved.
12-11
Rev.5
OFF IDLE SETTING
15. After warming the oil temp to the minimum required for takeoff power application, run the engine to full throttle and verify the engine is developing proper power with an indication of at least 4700 RPM. 16. Verify that both vacuum gauge readings are the same when the throttle is slowly moved between near idle and full power. Use of damping valves (see Figure 30) may be required to smooth out the vacuum gauge readings. Install valves if required and slowly close them until the vacuum gauge readings stop fluctuating rapidly. If the vacuum gauge readings are not the same, shut down the engine and verify that the choke controls on both carburetors are in the full off position. Also verify that both throttle cable leads (see Figure 27) are resulting in full travel of the throttle arms to the full throttle position on both carburetors. If both are satisfactory move to step 17 for making adjustments. 17. Determine which carburetor has the higher vacuum reading. Loosen the aft nut on the off idle adjustment hardware of the carburetor with the higher vacuum (see Figure 27) and then tighten the fwd nut. This will adjust the throttle (for this carburetor) open an additional amount. 18. Restart the engine and run the engine through the middle of the throttle range. Repeat the adjustment done in step 17 until the vacuum gauge readings for both carburetors are closely matched. If you go too far and the carburetor that you have been adjusting ends up having a vacuum gauge reading lower than the other reverse the adjustment and bring it back to where the vacuum gauge readings match. Once the off idle vacuum gauge readings are balanced confirm that the nuts on the throttle cable locking hardware are tight on both carburetors.
IDLE SPEED ADJUSTMENT
▲ WARNING: DO NOT ADJUST THE IDLE SPEED SCREWS MORE THAN 1/2 TURN EITHER WAY TO ACHIEVE THE PROPER IDLE SPEED! IF A SETTING OF MORE THAN 1/2 TURN IS REQUIRED, REPEAT STEPS 1-8.
IF NO SATISFACTORY RESULT CAN BE ACHIEVED INSPECT THE IDLE JET FOR TRANSLUCENT, JELLY-LIKE CONTAMINATION AND FREE PASSAGE. CLEAN AS REQUIRED.
12-12
Rev.5
● NOTE: WHEN CHECKING THE IDLE SPEED DURING THE ADJUSTMENT PROCEDURE ONLY PULL LIGHTLY ON THE THROTTLE CONTROL UNTIL YOU JUST FEEL THE IDLE STOPS ON THE CARBURETORS. A HEAVY PULL ON THE THROTTLE CONTROL WILL FLEX THE THROTTLE ARMS AND GIVE AN INACCURATE IDLE SPEED.
● NOTE: IF THE THROTTLE HANDLE IS HELD FULLY AT IDLE FOR AN EXTENDED PERIOD THE IDLE MAY CREEP DOWN TO APPROXIMATELY 1550 RPM. THIS IS PERMISSIBLE WHEN SETTING UP THE CARBURETORS BUT DURING NORMAL GROUND OPERATIONS THE IDLE SPEED SHOULD BE KEPT AT OR ABOVE 1650 RPM, OR WHATEVER IDLE SPEED IS REQUIRED TO ALLOW THE ENGINE TO RUN SMOOTHLY. OPERATING AT IDLE SPEEDS WHERE THE ENGINE IS MAKING A KNOCKING/RATTLE TYPE NOISE WILL CAUSE GEARBOX DAMAGE.
● NOTE: OFTEN TIMES WARMING THE ENGINE BY RUNNING IT ON THE GROUND DOES NOT QUITE BRING IT UP TO NORMAL OPERATING TEMPERATURES. THIS WILL HAVE A SLIGHT EFFECT ON WHAT THE ACTUAL IDLE RPM WILL BE ONCE THE AIRPLANE HAS BEEN FLOWN FOR A FEW MINUTES (FULLY WARMED UP). THE DIFFERENCE TENDS TO BE A 50 – 75 RPM INCREASE. FOR THIS REASON, UNLESS YOU ARE DOING THE CARBURETOR SYNCHRONIZATION PROCEDURE IMMEDIATELY AFTER FLYING THE AIRPLANE, ADJUSTING FOR AN IDLE SPEED NEAR THE BOTTOM OF THE RECOMMENDED RANGE WILL NET YOU A PROPER IDLE OF ABOUT 1650 RPM AFTER THE ENGINE IS FULLY WARMED.
● NOTE: VERIFY THE IDLE SPEED AND ADJUST AS NECESSARY TO ACHIEVE 1600- 1650 RPM AND SMOOTH ENGINE OPERATION (REMEMBER TO ONLY PULL LIGHTLY AGAINST THE CARBURETORS IDLE STOPS).
19. A final idle speed adjustment may be required by resetting the idle speed adjustment screws, accordingly. Turning the idle speed adjustment screw clockwise will increase the engine speed / counter clockwise will decrease it. Equal adjustments must be made to each carburetor. Any major adjustments require verification of all parameters in this procedure. Before moving on to the next step, verify that the vacuum gauge readings for the two carburetors are balanced at idle and at off idle throttle settings. 20. Use light pressure on the throttle control to hold it at the idle position, then tighten
12-13
Rev.5
the friction lock to hold the throttle control in place. Slide the CT-00101 Stop Nut back against the forward edge of the conduit in the orientation shown in Figure 27, then tighten the CT-00101 set screw. 21. Restart the engine and confirm that when the throttle is pulled hard to the idle stop the idle speed is correct and the vacuum gauge readings for the two carburetors are closely balanced. If they are not, loosen the CT-00101 Stop Nuts on both carburetors and then repeat steps 19 and 20 until they are. 22. Install the balance tube in the reverse sequence of removal. Any minor differences in balance at idle will be compensated for by the balance tube at low engine RPM.
VERIFY FUNCTIONALITY OF THROTTLE RETURN SPRINGS
1. This section must be done with the aircraft outside.
2. Chock main wheels, tie-down tail.
3. BRAKES: Apply FULL
4. Master switch "ON", avionics switch "ON" then power-down transponder, com radio, and GPS
5. Check EFIS for fuel pressure indication
6. Start engine, check for oil pressure functioning and showing pressure
7. Warm the engine to 122O F
8. THROTTLE- Completely loosen throttle friction knob and observe throttle advance rate.
If the throttle advances rapidly to a partial position, then slowly advances the throttle to full, the springs are functioning correctly. This may take up to 15 seconds.
If the throttle is not pulled to full, the return springs and/or throttle cable need to be replaced before further flight. Consult the RV-12 KAI Section 50.
12-14
Rev.5
THROTTLE RETURN SPRING REPLACEMENT Tools None Expendable None Replaceable SPRING-00002-L/R-1 Service Rating Line Minimum Certification Owner and SPC, LSA-RM or A&P Additional References KAI
REMOVAL 1. Remove SPRING-00002-L/R-1 as shown in KAI Section 50. INSTALLATION 1. Installation procedure is reverse of the removal procedure. 2. Perform the carburetor sync procedure found in this section.
12-15
Rev.5
SERVICE SCHEDULE PROCEDURES
COWL HINGE PIN LUBRICATION Tools #2 Phillips screwdriver Expendable Dry lubricant Replaceable None Service Rating Preventative Minimum Certification Owner and SPC, LSA-RM or A&P Additional References KAI 1. With the cowl hinge pins removed wipe each hinge pin clean. 2. Immediately prior to re-installation apply lubricant along the length of each hinge pin.
OIL HOSE REPLACEMENT ▲ WARNING: BEFORE PERFORMING ANY INSPECTION OR SERVICE ALLOW THE ENGINE COMPONENTS TO COOL. Tools 1/4, 3/8, 7/8 combo end wrenches, Phillips screwdriver , wire cutters Expendable Plastic tie-wrap 8in Replaceable Oil Supply Hose, Oil Cooler Hose, Oil Return Hose, Oil Tank Vent Tube, Oil Vent Interconnect Service Rating Preventative Minimum Certification Owner and SPC, LSA-RM or A&P Additional References KAI REMOVAL 1. Remove Cowl (12-4). 2. Drain oil system per Rotax Line Maint. Manual including draining of the oil cooler. 3. Cut tie-wraps and detach cushioned clamps from oil hoses. 4. Disconnect and remove oil hoses from the oil tank cover assembly, engine and oil cooler. 5. Remove Oil Tank Vent Tube and Oil Vent Interconnect.
INSTALLATION 1. Installation of new hoses and tubes is reverse of removal procedure. 2. Perform oil purge procedure detailed in Rotax Service Instruction SI-912-018.
12-16
Rev.5
COOLING HOSE REPLACEMENT ▲ WARNING: BEFORE PERFORMING ANY INSPECTION OR SERVICE ALLOW THE ENGINE COMPONENTS TO COOL. Tools 3/8 open end wrench, screwdriver, wire cutters Expendable Plastic tie-wrap 8in
Replaceable FF-1208A, FF-1208B, FF-1220 Service Rating Preventative Minimum Certification Owner and SPC, LSA-RM or A&P Additional References KAI
REMOVAL 1. Drain cooling system per Rotax Line Maint. Manual. 2. Disconnect cushioned clamps and cut tie wraps from coolant hoses. 3. Loosen hose clamps and slide them away from the component. 4. Disconnect hoses from reservoir, engine, and radiator. 5. Cut new hoses to same length as old ones. 6. Remove springs from old hoses and install in new hoses.
INSTALLATION 1. Installation procedure is reverse of removal procedure. 2. Refer to Rotax Line Maint. Manual to refill coolant.
MANIFOLD PRESSURE HOSE REPLACEMENT Tools Wire cutters, straight slot screwdriver(for prying hose) Expendable Tie wrap Replaceable Manifold pressure hose Service Rating Preventative Minimum Certification LSA-RM with Rotax Service certification or A&P with Rotax Service certification Additional References KAI
REMOVAL 1. Cut the tie wrap attaching the manifold pressure hose to the manifold pressure sensor wires. 2. Remove the hose from the manifold pressure sensor and the from the compensating tube assembly.
INSTALLATION 1. Cut the new hose to the length specified in the KAI. 2. Installation is reverse of removal.
12-17
Rev.5
CYLINDER, PISTON AND VALVE ASSEMBLY REMOVAL Tools 5 mm Allen wrench, 12,13 mm socket, wire cutters, pliers, #2 Phillips & straight slot screwdrivers, and others for engine disassembly Expendable Tie wraps, engine coolant Replaceable Coolant Hoses - reuse if serviceable, coolant Service Rating Heavy Minimum Certification LSA-RM with Rotax Maintenance certification or A&P with Rotax Maintenance certification Additional References KAI, Rotax Line and Heavy Maintenance Manuals
REMOVAL
▲ WARNING: ALLOW THE ENGINE AND APPLICABLE COMPONENTS TO COOL B EFORE PERFORMING SERVICE OR INSPECTION. HOT ENGINE COMPONENTS WI LL CAUSE SERIOUS BURNS.
1. Remove the exhaust system, see Exhaust System chapter. 2. Disconnect all wires and fuel pump drain tube from oil return tubes if/as required. 3. Disconnect oil pressure, EGT, and CHT wires from cylinder heads as required. See Rotax Line and Heavy Maintenance Manuals for the remaining steps: 4. Drain coolant; remove intake manifolds, water hoses, valve covers, cylinders, pistons, and valve assemblies.
INSTALLATION 1. Installation is reverse of removal. 2. Refill coolant system to recommended level.
12-18
Rev.5
ENGINE REPLACEMENT
Tools Torque wrench, many common tools as req'd. Expendable Loctite 221, coolant, engine oil Replaceable Service Rating Line Minimum Certification LSA-RM with Rotax Service certification or A&P with Rotax Service certification Additional References KAI, Rotax Line and Heavy Maintenance Manual
REMOVAL 1. Remove battery ground cable from negative battery terminal. 2. Remove exhaust system. See Exhaust System chapter. 3. Disconnect fuel pump drain tube and hose where attached to the engine. 4. Disconnect oil pressure, EGT, and CHT wires from cylinder heads. Cut tie-wraps securing wire runs to various engine components as required. 5. Move fuel selector valve to "UP-OFF" position. 6. Place suitable container under gascolator. Remove gascolator bottom plug and drain fuel from system. NOTE: This is a relatively slow process. 7. Disconnect fuel hose at firewall and gascolator. Some fuel may still be in hoses. 8. Place drain pan beneath engine and drain oil by disconnecting oil hose at pump. Elevate hose to prevent siphoning oil from tank. 9. Burp engine. 10. Disconnect oil return hose from bottom of engine case. 11. Disconnect oil return hose (where tank is marked "IN") from top of oil tank. 12. Drain cooling system per Rotax Line Maint. Manual. 13. Disconnect throttle and choke cables from carburetor per KAI.
Refer to KAI for remainder of engine removal steps.
INSTALLATION 1. Installation is reverse of removal. Torque fasteners as specified. 2. Refill coolant system to recommended level. 3. Refill oil to recommended level. 4. Purge oil system, etc. refer to the Rotax Line Maintenance Manual for this and other procedures during and after installation. Also refer to applicable KAI sections throughout the installation.
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Rev.5
THIS PAGE INTENTIONALLY LEFT BLANK
12-20
Rev.5
CHAPTER 13 - FUEL SYSTEM
OVERVIEW ...... 13-2 Components ...... 13-2 Fuel System Schematic ...... 13-3 SERVICE ...... 13-3 Supplies ...... 13-4 Tools ...... 13-4 Expendable ...... 13-4 Replaceable ...... 13-4 General ...... 13-4 Draining the fuel system ...... 13-4 Fuel tank removal ...... 13-5 Installation ...... 13-6 Fuel system component removal ...... 13-6 Installation ...... 13-7 Service Schedule Procedures ...... 13-7 Gascolator cleaning ...... 13-7 Installation ...... 13-7 Fuel strainer removal...... 13-8 Installation ...... 13-8 Fuel Return Assembly Replacement ...... 13-8 Fuel Pressure Hose Flush ...... 13-9 Fuel Drain Hose Replacement ...... 13-10
13-1
Rev.5
OVERVIEW The fuel system consists of a fuel neck and cap, 20-gallon fuel tank, tank sending unit, mechanical fuel gauge and electric fuel pump aft of the center section. The ES 40105 Electric fuel pump is a 12V DC solid-state pump. This serves as an auxiliary fuel pump. The VA-261 Fuel Strainer at the outlet of the fuel tank prevents any large foreign objects from proceeding into the rest of the fuel system. Forward of the center section, in order; there is the fuel valve, fuel flow transducer, gascolator, Engine driven fuel pump, and the fuel manifold. The fuel valve provides the ability to permit or prevent fuel flow to the fuel system downstream of the fuel valve. The manifold feeds the fuel pressure sender, fuel return line and the left and right carburetors. The gascolator serves as the primary fuel filter and water trap. Sample the gascolator sump frequently to monitor the amount of water introduced into the fuel system. The gascolator and fine fuel screen requires inspection and cleaning at regular intervals (at least annually).
• NOTE: This maintenance manual is intended to be used in conjunction with the RV-12 Kit Assembly Instructions (KAI) when completing maintenance or repair processes.
COMPONENTS Quantity Part or Assembly Name Part Number or Reference 1 Fuel cap T-406A 1 Fuel neck T-1211 1 Fuel tank See KAI 1 Fuel strainer VA-261 1 Electric fuel pump ES 40105 1 Fuel valve 4161089 1 Gascolator GAS-5 1 Fuel quick-drain CAV-110 1 Fuel flow transducer Flo-Scan or FT-60 1 Fuel sending unit IE F-385B 1 Left carburetor See Rotax Documentation 1 Right carburetor See Rotax Documentation 1 Mechanical fuel pump See Rotax Documentation 1 Fuel pressure sender See KAI 1 Mechanical Fuel Gauge IE-00001
13-2
Rev.5
FUEL SYSTEM SCHEMATIC
SERVICE
▲WARNING: ALWAYS HAVE AN APPROPRIATE FIRE EXTINGUISHER READILY AVAILABLE. ▲WARNING: BEFORE PERFORMING ANY MAINTENANCE OR REPAIRS TURN THE MASTER SWITCH 'OFF' AND DISCONNECT THE NEGATIVE (-) BATTERY CABLE FROM THE BATTERY. ■ CAUTION: REPLACEMENT FUEL SYSTEM COMPONENTS MUST BE EQUIVALENT TO THE ORIGINAL PARTS. ● NOTE: CLOSE THE FUEL VALVE TO SERVICE OR REMOVE COMPONENTS THAT ARE FORWARD OF THE FUEL VALVE. DRAIN THE FUEL SYSTEM TO SERVICE OR REMOVE COMPONENTS AFT OF THE FUEL VALVE.
13-3
Rev.5
SUPPLIES
TOOLS EXPENDABLE Sockets: Safety wire ▪ 1/4 ▪ 3/8 ▪ 5/16 REPLACEABLE ▪ 7/16 Gas-5 Screen Combination wrench: Gas-5 O-ring gasket ▪ 3/8 ▪ 7/16 ▪ 1/2 ▪ 11/16 ▪ 3/4 ▪ 9/16 Screwdriver ▪ #2 Phillips ▪ 3/16 Standard ▪ Hex. flat blade screw bit Safety wire pliers Fuel Container 1/2 ID fuel hose
GENERAL
▲WARNING: ALWAYS HAVE AN APPROPRIATE FIRE EXTINGUISHER READILY AVAILABLE. ▲WARNING: BEFORE PERFORMING ANY MAINTENANCE OR REPAIRS TURN THE MASTER SWITCH 'OFF' AND DISCONNECT THE NEGATIVE (-) BATTERY CABLE FROM THE BATTERY.
DRAINING THE FUEL SYSTEM Tools 1/2, 3/4 combo wrench Fuel Container Expendable 1/2 ID fuel hose Replaceable None Service Rating Preventative Minimum Certification Owner and SPC, LSA-RM or A&P Additional References KAI
• NOTE: IF THERE IS A FAIR AMOUNT OF FUEL IN THE TANK, REDUCE THE DRAIN TIME BY
13-4
Rev.5
FIRST SIPHONING OUT AS MUCH AS POSSIBLE. A SMALL WEIGHT SECURELY ATTACHED TO THE END OF A FLEXIBLE SIPHON HOSE WORKS WELL FOR REACHING THE TANK'S BOTTOM FORWARD END.
1. Put the fuel valve in the ‘OFF’ position. 2. Remove the engine cowling. (12-4) 3. Place a container beneath the gascolator with sufficient capacity for the fuel in the fuel tank.
• NOTE: POSITION A RAG UNDER THE GASCOLATOR FITTING TO CATCH SPILLED FUEL . IMMEDIATELY AFTER DISCONNECTING THE HOSE MOVE IT UPWARD AND POSITION THE END AS HIGH AS POSSIBLE TO MINIMIZE THE LOSS OF FUEL FROM THE HOSE.
4. Disconnect the fuel hose from the 90° fitting on the output side of the gascolator. 5. Temporarily connect a length of 1/2” ID hose to the 90° fitting. Place the loose end in the fuel container. 6. Put the fuel valve in the ‘open’ position. 7. Remove the fuel cap from the fuel neck.
■ CAUTION: TURN OFF THE ELECTRIC FUEL PUMP IMMEDIATELY WHEN A CHANGE IN SOUND IS HEARD, (THE LOUDER CLACKING SOUND INDICATES THE FUEL PUMP IS NO LONGER PUMPING FUEL) DO NOT ALLOW THE FUEL PUMP TO OPERATE WITHOUT FUEL OR PERMANENT DAMAGE MAY OCCUR.
8. Turn on the master switch and operate the ES 40105 Electric Fuel Pump until the fuel pump stops pumping fuel. 9. Put the fuel cap back in place in the fuel filler opening but do not latch it. Just allow the cap to lay in the opening. To aid in clearing the fuel lines use low pressure (5-10 PSI max) air applied to the open end of the fuel hose that was disconnected from the gascolator's outlet fitting.
Repeat the previous two steps several times, waiting for about 30 seconds between repitions to give the fuel time to flow past the tank's internal baffle.
Also, the fuel valve may be partially closed, reducing the flow rate to equal or slightly less than the tank drainage rate (for fuel behind the internal baffle), helping to reduce the number of 'run - wait' cycles. 10. Reconnect the fuel line at the gascolator.
FUEL TANK REMOVAL Tools 5/16, 3/8, 7/16 socket 11/16, 9/16 combo wrench
13-5
Rev.5
#2 Phillips screwdriver 3/16 Standard screwdriver Expendable None Replaceable None Service Rating Line Minimum Certification LSA-RM or A&P Additional References KAI
1. Drain the fuel system. (13-4) 2. Remove the two aft access covers from the fuselage bottom skin. (3-4) 3. Remove the screws (6) that attach the fuel neck to the fuselage. Loosen the hose clamps and slide the rubber collar up to remove the fuel neck from the fuselage and fuel tank. 4. Disconnect the fuel sending unit wire. 5. Remove the ELT Antenna Bracket, disconnect the coax cable and set aside.
■ CAUTION: DOUBLE WRENCH DURING THE REMOVAL OF THE SMALLER OF THE TWO FUEL LINES TO PREVENT ACCIDENTAL ROTATION OF THE FITTING IN THE FUEL TANK.
6. Disconnect the two fuel lines from the bottom of the tank. 7. Remove the two bolts from the forward fuel tank attach bracket. 8. Remove the bolt from the aft fuel tank attach bracket. 9. Remove the fuel tank.
INSTALLATION 1. Installation procedure is reverse of the removal procedure.
FUEL SYSTEM COMPONENT REMOVAL ▲WARNING: BEFORE PERFORMING ANY MAINTENANCE OR REPAIRS TURN THE MASTER SWITCH 'OFF' AND DISCONNECT THE NEGATIVE (-) BATTERY CABLE FROM THE BATTERY.
Tools 3/8, 7/16 sockets 3/8, 7/16 combination wrenches Expendable None Replaceable None Service Rating Line Minimum Certification LSA-RM or A&P Additional References KAI 1. Isolate the component from fuel flow with either the fuel shutoff valve or by draining the fuel tank.
13-6
Rev.5
2. Label, then disconnect the electrical connections attached to the component, if applicable. 3. Disconnect the fuel line(s) attached to the component, if applicable. 4. Remove the attaching hardware and component.
INSTALLATION 1. Installation procedure is reverse of the removal procedure.
SERVICE SCHEDULE PROCEDURES
▲WARNING: ALWAYS HAVE AN APPROPRIATE FIRE EXTINGUISHER READILY AVAILABLE.
GASCOLATOR CLEANING Tools 3/16 Standard screwdriver ¼” drive socket extension, ¼” socket, flat blade screw bit Safety wire pliers Fuel catch container Expendable Safety wire Replaceable Gas-5 Screen Gas-5 O-ring gasket Service Rating Preventative Minimum Certification Owner and SPC, LSA-RM or A&P Additional References KAI 1. Remove the engine cowling. (12-4) 2. Move the fuel valve to the OFF position. 3. Remove the fuel quick-drain to drain the existing fuel from the gascolator bowl. 4. Remove the safety wire and screws (4) from around the gascolator bowl. (Note: The inboard aft screw can be accessed through the hole provide in the bottom plate of the nose gear assembly by using a ¼” drive socket extension, a ¼” socket, and a screw bit inserted in the socket). 5. Remove the collar and the gascolator bowl. (Note: Have a container available to catch any spillage of fuel that still remains in the gascolator and fuel lines). 6. Use a small pointed tool to lift the edge of the filter screen and remove it for cleaning.
INSTALLATION: 1. Installation procedure is reverse of the removal procedure.
13-7
Rev.5
FUEL STRAINER REMOVAL Tools 3/4 combo wrench or deep socket Expendable Thread sealant paste Replaceable None Service Rating Line Minimum Certification LSA-RM or A&P Additional References KAI NOTE: IT IS NOT NECESSARY TO REMOVE THE FUEL TANK IN ORDER TO REMOVE THE FUEL STRAINER. 1. Drain the Fuel System. (13-4) 2. Remove the two aft access covers from the fuselage bottom skin. (3-4) 3. Disconnect the fuel line (forward most fitting) from the bottom of the tank. 4. Remove the fuel strainer. 5. Clean the screen and inspect same for breakage or separation from fitting.
Installation: 1. Installation procedure is reverse of the removal procedure. Apply thread sealant paste to fuel strainer pipe threads before installation.
FUEL RETURN ASSEMBLY REPLACEMENT Tools 2X 9/16, 11/16, 7/8, 14mm open end wrench 12mm socket, torque wrench(in-lb) , wire cutters Expendable Plastic tie-wrap 8in Replaceable Fuel Return Assembly Service Rating Preventative Minimum Certification LSA-RM with Rotax Service certification of A&P with Rotax Service Certification Additional References KAI NOTE: WHEN LOOSENING OR TIGHTENING THE BANJO BOLT SUPPORT THE CLAMP BLOCK (FUEL MANIFOLD) APPROPRIATELY.
1. Drain fuel system forward of fuel valve. (13-4) 2. Disconnect both ends of Fuel Return Assembly. 3. Remove banjo bolt M8X1X17 from top of clamp block. 4. Cut tie-wraps and remove Fuel Return Assembly.
Installation: 1. Installation of new hose assembly is reverse of removal procedure. Rotax specifies that new copper crush washers be used. 2. Torque banjo bolt M8X1X17 to 90 in-lbs.
13-8
Rev.5
Figure 31: Fuel Pressure Hose Flush
FUEL PRESSURE HOSE* FLUSH (* Left Side of Fuel Return Assembly) Tools 2X 9/16 combination wrenches Expendable Fuel, rags, temporary fuel container Replaceable NA Service Rating Preventative Minimum Certification LSA-RM with Rotax Service certification or A&P with Rotax Service certification Additional References KAI
Removal 1. Place rags beneath the Fuel Pressure Sender. 2. Loosen VA-216 Fuel Return Assembly hose coupling while supporting elbow with second wrench. 3. Place container beneath hose and remove hose from fitting. 4. With end of hose inside container, flush hose by turning on fuel boost pump for two seconds.
Installation 1. Reinstall hose to elbow.
13-9
Rev.5
FUEL DRAIN HOSE REPLACEMENT Tools 1/4 socket or Phillips screwdriver Expendable Tie wraps (2) Replaceable Fuel interconnect and drain hoses Service Rating Preventative Minimum Certification LSA-RM with Rotax Service certification or A&P with Rotax Service certification Additional References KAI
Removal 1. Cut the tie wraps attaching the drain hose to the gascolator-to-fuel-pump hose. 2. Loosen two hose clamps on the interconnect hose and one clamp on the drain hose and slide the clamps onto the aluminum drain tube. 3. Remove the hoses.
Installation 1. Install new hoses onto the fuel pump drain fitting and the drain tube. 2. Slide hose clamps back into position over the hoses and tighten. 3. Secure the drain hose to the gascolator-to-fuel-pump hose using tie wraps.
13-10
Rev.4 CHAPTER 14 - EXHAUST SYSTEM
OVERVIEW ...... 14-2 Components ...... 14-2 SERVICE ...... 14-3 Supplies ...... 14-3 Tools ...... 14-3 Expendable ...... 14-3 Replaceable ...... 14-3 General ...... 14-3 Exhaust system removal ...... 14-3 Installation ...... 14-3 Service Schedule Procedures ...... 14-4 Ball joint lubrication ...... 14-4
14-1 Rev.4
OVERVIEW The primary purpose of the exhaust system is to direct engine combustion gasses and heat away from the aircraft, components and occupants. The purpose of the muffler is to reduce engine noise.
• NOTE: THIS MAINTENANCE MANUAL IS INTENDED TO BE USED IN CONJUNCTION WITH THE RV-12 KIT ASSEMBLY INSTRUCTIONS (KAI) WHEN COMPLETING MAINTENANCE OR REPAIR PROCESSES.
SB-00005 EXHAUST COMPONENTS Quantity Part or Assembly Name Part Number or Reference 1 Cylinder #1 Exhaust EX-00015-1 1 Cylinder #2 Exhaust EX-00017-2 1 Cylinder #3 Exhaust EX-00016 1 Cylinder #4 Exhaust EX-00018 1 Muffler EXH-12 8 Joint spring 938 795 8 Exhaust M8-WS12 Lock Nut 842 950
EX-00044 EXHAUST COMPONENTS Quantity Part or Assembly Name Part Number or Reference 1 Cylinder #1 Exhaust EX-00044A 1 Cylinder #2 Exhaust EX-00044B 1 Cylinder #3 Exhaust EX-00044C 1 Cylinder #4 Exhaust EX-00044D 1 Muffler EX-00044E 8 Joint spring 938 795 8 Exhaust M8-WS12 Lock Nut 842 950
14-2
Rev.4
SERVICE
SUPPLIES
TOOLS EXPENDABLE 13 mm socket Anti-seize compound, high temp Locking pliers Exhaust M8-WS12 Lock Nuts
REPLACEABLE See component list above except M8 Nuts.
GENERAL
EXHAUST SYSTEM REMOVAL
▲ WARNING: ALLOW THE EXHAUST COMPONENTS TO COOL BEFORE PERFORMING INSPECTION OR SERVICE.
Tools 13 mm socket Locking pliers Expendable Anti-seize compound, high temp M8-12WS Nuts Replaceable Joint spring Service Rating Line Minimum Certification LSA-RM or A&P Additional References KAI
1. Remove the engine cowling. (12-4) 2. Remove the muffler attachment springs (8) and muffler. Note: To avoid nicking the springs clamp a short loop of safety wire in locking pliers. Hook the loop onto the spring and then pull to remove the spring. 3. Remove the two nuts and the exhaust tube from each cylinder exhaust port.
INSTALLATION 1. Lubricate the ball joints and all exhaust hardware. (14-4) 2. Installation procedure is reverse of the removal procedure.
14-3
Rev.4
SERVICE SCHEDULE PROCEDURES
BALL JOINT & SLIP JOINT LUBRICATION
▲ WARNING: ALLOW THE EXHAUST COMPONENTS TO COOL BEFORE PERFORMING INSPECTION OR SERVICE.
Required tools Locking pliers Required expendables Anti-seize compound Replaceable None Service rating Line Minimum Certification LSA-RM or A&P Additional Reference KAI
1. Remove the muffler attachment springs (8) and muffler. Note: Use locking pliers for a tight grip on the springs during removal and installation. 2. Apply a light coating of anti-seize compound to the Cylinder #1 Exhaust slip joints. 3. Apply a generous amount of anti-seize compound to the exhaust tube where it meets the muffler flange. 4. Reinstall the muffler.
14-4
Rev.1
CHAPTER 15 - PAINTING AND COATINGS
OVERVIEW ...... 15-2 SERVICE ...... 15-3 Supplies ...... 15-3 Tools ...... 15-3 Expendable ...... 15-3 Replaceable ...... 15-3 Service Schedule Procedures ...... 15-3 Powder coat repair ...... 15-3 Primer repair ...... 15-4 Decorative paint repair...... 15-5
15-1
Rev.1
OVERVIEW
● NOTE: REFER TO KAI – SECTION 4 AND 5 FOR ADDITIONAL INFORMATION.
The aluminum skins used on RV aircraft are all 2024-T3 alloy. They are "alclad" meaning both sides of the sheet are coated with pure aluminum during manufacture. The thickness of the alclad layer on aluminum sheet 1/16 inch thick or less is 5% of the sheet thickness. Alclad on aluminum sheet greater than 1/16 inch thick is 2.5% of the sheet thickness. All non-alclad aluminum parts such as 6061-T6 must be primed for corrosion protection. Aluminum tubing (other than fluid lines) must be primed on both the interior and exterior surfaces. Aluminum bar, angle and tube used in the RV-12 are not alclad and must be primed to ensure corrosion resistance. Zinc Chromate has been the traditional primer used on aircraft aluminum. With proper surface cleaning this is still a good choice. There are however many superior primers now available. Most of these are two part, catalytic curing primers. Generally speaking it's preferable to replace a coated part with a coated part.
Following is a partial list of suitable primers:
DUPONT VERI-PRIME (PRIMER #615 and CONVERTER #616S)
DITZLER DP-40/50 EPOXY PRIMER
TEMPO brand Chromate in a spray can
PRATT & LAMBERT Vinyl Zinc Chromate, EX-ER-7 and T-ER-4 Reducer
SHERWIN WILLIAMS WASH PRIMER #P60G2 and Catalyst Reducer #R7K44
MARHYDE self-etching primer, available in a spray can as well as quarts
Decorative paint on the structure of the aircraft can be touched-up by the sport pilot certified owner or a certified repairman with ‘maintenance’ rating. Control surfaces can only be repainted by an LSA repairman with a ‘maintenance’ rating or an A&P. Part replacement must be consistent with the original KAI from Van’s Aircraft. Priming factory alclad replacement parts remains at the repairmans discretion. Non- alclad parts must be primed per the KAI. Any parts that require replacement due to corrosion warrant additional corrosion protection on the replacement part. When in doubt, prime the part.
15-2 Rev.1
SERVICE
▲ WARNING: PAINT OR SOLVENT MUST USED IN ACCORDANCE WITH THE MANUFACTURERS INSTRUCTIONS. ▲ WARNING: DO NOT USE ANY TYPE OF BODY FILLER ON THE AIRCRAFT. ▲ WARNING: DO NOT DAMAGE ANY RIVET HEADS WHEN PREPARING A SURFACE FOR TOUCH-UP PAINT. ■ CAUTION: EXPOSED STEEL MUST BE CLEANED AND COATED WITH PRIMER OR POWDER COAT TOUCH-UP PAINT. ■ CAUTION: ANY SCRATCH THAT MAY HAVE PENETRATED THE ALCLAD COATING MUST BE CLEANED AND PRIMED PROPERLY.
SUPPLIES
TOOLS EXPENDABLE Scouring pad Touch-up paint Sandpaper (various grades) Primer Decorative touch-up paint REPLACEABLE None
SERVICE SCHEDULE PROCEDURES
POWDER COAT REPAIR
▲ WARNING: IF CRACKS, PENETRATING RUST OR CORROSION ARE FOUND IN THE COATING SURFACE OF POWDER-COATED, PRIMED OR PAINTED PARTS, THE PART SHOULD BE CAREFULLY INSPECTED UNDER THE COATING FOR MATERIAL DAMAGE. IF IN DOUBT THE PART SHOULD BE REPLACED.
15-3
Rev.1
Tools Sandpaper Expendable Touch-up paint Replaceable None Service Rating Line Minimum Certification Total area 4 in² or less - Owner and SPC Total area greater than 4 in² - LSA-RM or A&P Additional References KAI 1. Use coarse grit sandpaper to remove the entire area of loose, stained or cracked coating. Discolored powder coat could conceal underlying rust damage and requires removal. 2. Gradually progress to finer grit sandpaper to achieve a smooth, gradual taper to undamaged coating. 3. Clean and dry the entire prepared area. 4. Apply touch-up paint to the entire prepared area.
PRIMER REPAIR
● NOTE: WHEN PRIMING A REMOVABLE PART BETTER RESULTS CAN BE ACHIEVED BY REMOVING THE PART.
Tools Sandpaper Expendable Primer Replaceable None Service Rating Line Minimum Certification Static structure: Total area 56 in² or less - Owner and SPC Total area greater than 144 in² - LSA-RM or A&P Control surface: Total area 10 in² or less - Owner and SPC Total area greater than 10 in² - LSA-RM or A&P Additional References KAI 1. Remove any loose or damaged primer. 2. Use progressively finer grit sandpaper to achieve a smooth, gradual taper to undamaged primer. 3. Clean and dry the entire prepared area. 4. Apply primer to the entire prepared area.
15-4 Rev.1
DECORATIVE PAINT REPAIR
■ CAUTION: ANY SCRATCH THAT HAS PENETRATED TO THE METAL MUST BE CLEANED AND PRIMED PRIOR TO APPLYING DECORATIVE PAINT. ● NOTE: WHEN PRIMING A REMOVABLE PART BETTER RESULTS CAN BE ACHIEVED BY REMOVING THE PART.
Tools Sandpaper Expendable Applicable touch-up paint Replaceable None Service Rating Line Minimum Certification Static structure: Total area 64 in² or less - Owner and SPC Total area greater than 64 in² - LSA-RM, or A&P Control surface: Total area 16 in² or less - Owner and SPC Total area greater than 16 in² - LSA-RM, or A&P Additional References KAI 1. Remove any loose or damaged paint. 2. Use progressively finer grit sandpaper to achieve a smooth, gradual taper to undamaged paint. 3. Clean and dry the entire prepared area. 4. Apply primer and touch-up paint to the entire prepared area.
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15-6
Rev.1
CHAPTER 16 - TROUBLESHOOTING
Symptom Possible Causes Related Chapter Recurring blown fuse Short in circuit 8 Overloaded circuit
Engine will turn over, Insufficient ignition source 8 fails to start Insufficient fuel supply to engine 13
Insufficient air supply to engine 12
Engine fails to turn Insufficient battery power over Blown ‘Start’ fuse 8 Master or starter relay malfunction
Starter malfunction
Heater air is cool Low engine coolant
Engine below operating temperature. 12 Blockage in coolant system
Air leak around heater box
Vent door stuck Damage to fuselage 3
Damage to vent 5
Over tightened vent hardware KAI
Wing attach pin very Insufficient lubrication 5 difficult to insert or Structural damage 3 remove Wing not fully inserted 5
Force applied to wing
Pulls to one side during Low tire pressure 1 taxiing (level surface) Dragging brake 7
Damage to landing gear KAI
Axle nut over tightened KAI
Difficult to turn while Brake malfunctioning 7 taxiing Nose fork over tightened KAI
Shudder after touch- Nose fork under tightened 5 down
16-1
Rev.1
Symptom Possible Causes Related Chapter
Vibration at idle Propeller installed incorrectly 11
Idle RPM too low 12
Carb. sycronization out of balance Rotax line maint.
Engine suspension loose 3
Vibration at specific Carburetor malfunction 12 RPM Ignition malfunction Rotax line maint.
Excessive rattling Loose fasteners 3 Loose baggage
Corrosion Loose electrical connection 8
Exposure to contamination 3
Failing protective coating 15
Unlike metals exposed to moisture 15
Flight control Insufficient lubrication 2 resistance Control surface hinge axis not aligned 5-17
Failing control system components 6
Improper control system adjustments KAI
Erroneous engine Malfunctioning sensor 8 status Loose connection 3
Malfunctioning EMS 9
Abnormal engine noise Damaged or leaking exhaust system 14
Open passage in firewall 3
16-2
Rev.4
CHAPTER 17 - FEEDBACK & REPLACEMENT PARTS
FEEDBACK To maintain the highest level of safety the FAA requires and Van’s Aircraft Inc. requests notification of any safety of flight issue, service or maintenance difficulty that could compromise airworthiness of the RV-12 aircraft. A feedback form is provided in the Supplement section of this manual. A valuable description will include: • Specific flight condition if applicable. • List of the parts identified as affected by the anomaly. • Description of the apparent condition of the parts prior to the anomaly (de-burred, primed, modified, etc.) • Statement as to whether the aircraft has remained within the operating limitations defined in the POH. • Brief description of the type and frequency of aircraft use (may include; runway conditions, flying conditions, storage methods, etc.)
REPORTING METHODS Mail to: ATTN: RV-12 Safety Alert Van's Aircraft, Inc. 14401 Keil Road, NE Aurora, OR 97002 USA
Fax to: 'RV-12 Safety Alert' (on cover page) 503.678.6560 Hours: 24 hours per day
E-mail to: 'RV-12 Safety Alert' (in subject line) [email protected]
17-1
Rev.4
REPLACEMENT PARTS
Van's Aircraft Inc. reserves the right to update, modify or discontinue any part without notice. Van's Aircraft Inc. is not liable for the use of any part or material by the owner that does not appear on the kit's part list. Use of any unauthorized part or material will be at the owner/operators own risk. For replacement parts contact Van's Aircraft Inc. using the following information:
Van's Aircraft, Inc. Phone: 503.678.6545 14401 Keil Road, NE Fax: 503.678.6560 Aurora, OR 97002 USA Website: www.vansaircraft.com email: [email protected]
Part number and description may be obtained from the Kit Assembly Instructions. Whenever ordering replacement parts please provide the following information:
▪ Name ▪ Builder Number ▪ Day Phone ▪ Fax (if applicable) ▪ Email ▪ Ship to Address: ▪ Address ▪ City ▪ State/Province ▪ Zip/Postal Code ▪ Country ▪ part number ▪ description ▪ quantity ▪ payment method and corresponding account #, & exp. date (if applicable)
17-2
Rev.4
SUBSTITUTE PARTS
The following parts are approved for substitution. Either the original part or substitute part is acceptable for installation in the aircraft.
Brake System F 271-N-04X02 Male Nylon Tee ↔ Van's FLF-00004 Male Nylon Tee ↔ MCMASTER- CARR 5779K204 ↔ LEGRIS 3103 56 11
Avionics System FN4MC-2 Nylon 1/4 Straight ↔ Van's FLF-00007 Elbow ↔ MCMASTER CARR 5779K151 ↔ LEGRIS 3109 56 11
SV-D1000 (T) ↔ SV-HDX1100
Oil System (Note: There was no 'original part' in this case.) FUMOTO F107N 12mm-1.75 Quick Oil Drain Plug ↔ CCA-2450 Valve and CCA-2474 Extension ↔ SAF-AIR M12175 Valve and RM12175 Extension.
Torx Drive Screw AN526C832-R8 Phillips Truss SS X 1/2 in ↔ Fastenal 0175181 Torx, Pan Head, SS X 1/2 in (0175180, 3/8 in) NOTE: May be used in place of screws that hold all interior panels.
Rivets AN470AD rivets may be substituted for specified LP4 rivets.
AN426AD4 rivets may be substituted for specified CS4 rivets
Cherry Max CR series rivets may be substituted for any AN470AD rivet or LP4 rivet.
CCR rivets and solid AN426AD3 rivets, used for attaching nutplates, may be used interchangeably. AN426AD3 rivets are preferred for strength wherever they can be accommodated.
17-3
Rev.4
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17-4
Rev.10 CHAPTER 18 - SUPPLEMENT
SERVICE SCHEDULE CHECKLIST...... 18-3 INSPECTION CHECKLIST...... 18-7 ELECTRICAL SYSTEM SCHEMATIC...... 18-23 3 VIEW...... 18-25 FEEDBACK FORM...... 18-27
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Rev.10
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18-2
Rev.10 SERVICE SCHEDULE CHECKLIST Service What Action When How Date Initial Aircraft Inspection Annual or 100 hours 3-1 AST attach hinge Lubricate Annual or 100 hours 5-24 Battery Charge As needed 8-13 Battery terminals Clean As needed 8-13 Brake fluid Flush & replace 5 years 7-5 Brake pedal components Lubricate 2 years or 200 hours 7-4 Brake shoe linings Replace As needed 7-6 Cable end hardware Lubricate Annual or 100 hours 6-8 Control system rod ends Lubricate Annual or 100 hours 6-8 Coolant Hoses Replace 5 years 12-15 Dynon Check for Annual or as needed Dynon user’s manual updates ELT Self-Test 3 Months See Mfr’s Manual ELT Inspection 12 Months See Mfr’s Manual ELT Remote Control Panel Replace 5 years See Mfr’s Manual Battery Alkaline ELT Remote Control Panel Replace 10 years See Mfr’s Manual Battery Lithium ELT Audio Alert Indicator Replace 10 years See Mfr’s Manual Battery Engine service procedures Check & perform 100 hours Rotax maintenance manual Exhaust ball joints Lubricate Annual or 100 hours 14-4 Flaperon bearings Lubricate 6 months or as needed 5-24 Flaperon control connection Lubricate Each removal 5-23 Fuel Drain Hose Replace 5 years or with fuel 13-10 pump Fuel Strainer Clean & inspect Annual or 100 hours 13-8
18-3
Rev.10
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18-4
Rev.10 SERVICE SCHEDULE CHECKLIST (CONTINUED) Service What Action When How Date Initial Fuel Drain Interconnect Replace 5 years or with fuel 13-10 pump Fuel Return Assembly Replace 10 years or engine 13-8 overhaul Fuel Pressure Hose Flush Annual or 100 hours 13-9 Garmin Check for updates Annual or 100 hours Garmin user’s manual Gascolator Clean Annual or 100 hours 13-7 Landing gear attach hardware Torque Annual or 200 hours 3-11 Main wheel bearings Lubricate 2 years or as needed 5-25 Manifold Pressure Hose Replace 10 years or engine 12-16 overhaul Nose fork pivot Lubricate Annual or 100 hours 5-26 Nose wheel bearings Replace As needed 5-24 Wheel Balance Balance As needed 5-26 Oil Supply Hoses Replace 10 years or engine 12-14 overhaul Propeller Hub Clamping Bolts Torque Annual or 100 hours 11-3 Wing attach locations Lubricate Each removal 5-23 Wing interface terminal tabs Clean Annual or 100 hours 8-13 Throttle Return Springs Verify Function 50 hours or after 12-14 carburetor maintenance End of service schedule
18-5
Rev.10
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18-6
Rev.10 INSPECTION CHECKLIST RV-12 Aircraft Inspection Reg. Number: Airframe S/N: Engine S/N: Airframe TT: Engine TT: Inspection Date: Inspector: Check all that apply to inspector and inspection: ____ Owner ____ Operator ____ Pilot ____ A&P ____ LSA Repairman Inspection ____ LSA Repairman Maintenance ____ 100 hour ____ Annual ____ Extreme Conditions ____ After Hard Landing
Category: Check: Documents Pass Fail Certificate of Airworthiness Onboard and Displayed Registration Onboard and Accurate POH Onboard Operating Limitations Onboard Switch and control placards Secure / Legible Identification Plate Secure / Legible / Accurate Light Sport Placard (Experimental for E-LSA) Displayed Weight & Balance / Equipment List Onboard Service Schedule Items due for service
Systems & Controls Test Operations / Values Pre-Inspection Post-Inspection Engine Start Procedure Effective / Complete Starter Operational / Strong Oil Pressure & Temperature @ 1800 RPM Engine Run-Up Refer to Rotax Line Maintenance Manual Continued next page
18-7
Rev.10
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18-8
Rev.10
Oil Pressure & Temperature Pre-Values: Pressure______Temp______Post-Values: Pressure______Temp______Left and Right CHT (idle & operating temp) Pre-Values: Left______Right______Post-Values: Left______Right______Left and Right EGT (idle & operating temp) Pre-Values: Left______Right______Post-Values: Left______Right______Left and Right Wing Secure / Smooth operation of ailerons and flaps Brake System Operation Fuel Correct Indication Idle RPM at normal operating temp. ______@ RPM Verify function of throttle return springs Springs pull throttle to wide open with friction control off (see procedure page 12-14) Static RPM at full throttle Operational / RPM ______Electrical System Operational / Volts: ______Amps:______Cool Down & Shut Down Effective / Normal Fluids (Oil, Hydraulic, Fuel, Coolant) Leak / Level Check Stall warning Tone present in headphones when stall sense switch is lifted Angle-Of-Attack System Pressure Check Continued next page
18-9
Rev.10
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18-10
Rev.10 Notes:
Cockpit Check Pass Fail Aft Face of Firewall Cracks / Deformation Canopy Latch Security / Cracks / Proper operation Fwd & Aft Canopy Cracks / Deformation / Deterioration Pre-Inspection procedure Step 1-5 (Page 3-3) Seats & Seat/Shoulder Harness Wear / Fraying Cockpit Control Markings Clear / Correct Roll Bar and canopy frame Cracks / Deformation Continued next page
18-11
Rev.10
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18-12 Rev.10 Cockpit Control markings Clear / Correct Control Panel Security / Connections Fuses Security / Condition / Spares Control Cable Links & Push / Pull Rods Tension / Wear / Fatigue Control Stops Security / Deformation / Alignment Flight Control Cables Swages / Kinks / Interference / Alignment Engine Control Cables Operation / Kinks / Interference / Alignment Cable Pulleys Smooth Operation / Alignment / Security Control Stick Smooth Operation Flap Lever Smooth Operation Air & Heat Vents Operation / Security Wiring Harness Condition / Connections / Continuity System Lines (Fuel, Brake, Static) Security / Routing / Condition / Fittings Fuel System Components Security / Leaks Fuel Strainer Clean/Secure Rudder Pedals & Brakes Operation / Security
Avionics & Radio Inspect per Manufacturer Manual Pass Fail Each Main Unit Condition / Security Wiring & Conduit Chafing / Routing / Security Connections Corrosion / Security Antenna Mounts Condition / Security
Optional Equipment Throughout Inspect per Manufacturer Manual Pass Fail
Continued next page
18-13
Rev.10
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18-14
Rev.10
Emergency Locator Transmitter Comply with current FAR 91.207 Pass Fail "G" Switch Also refer to current CFR 91.207 Calendar date Also refer to current CFR 91.207 Battery Condition Also refer to current CFR 91.207 Audio Alert Indicator Battery See Manufacturer’s Manual Remote Control Panel Ind. Battery See Manufacturer’s Manual Self-Test See Manufacturer’s Manual
Propeller Refer to Sensenich Manual Pass Fail Spinner / Back-plate Cracks / Deformation Blades Delamination / Cracks / Damage Hardware Condition / Torque Hub Fasteners / Security Gear Box Leaks / Fasteners / Security Prop Track Perpendicular to Axis Continued next page
18-15
Rev.10
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18-16
Rev.10
Engine Refer to Rotax Manual Pass Fail Engine and components Comply with Rotax manufacturer inspection recommendations (Rotax Line Maintenance Manual)
Firewall Forward Fasteners / Deformation / Corrosion Pass Fail Fwd Face of Firewall Deformation / Cracks / Unsealed holes Studs & Nuts Torque / Condition Engine Mount Cracks / Signs of Fatigue / Corrosion Vibration Isolators Cracks / Deterioration Mount & Isolator Hardware Condition / Torque Wiring Harness Condition / Connections / Continuity Battery Condition / Corrosion / Security / Charge Cylinder Cooling Shroud Security / Condition Cabin Heat Door Security / Condition / Operation Left Carburetor Condition / Secure Connections Right Carburetor Condition / Secure Connections Carburetor Drip Trays Cracks / Deformation System Lines (Fuel, Pitot) Security / Routing / Condition Gascolator Security / Contamination / Leaks Control Cables (throttle, choke, etc) Operation / Condition / Connection Air Filters (left & right) Clean / Secure Heat Exchangers (oil & coolant) Leaks / Condition / Security Exhaust System Leaks / Condition / Security Cowling Condition / Fasteners
Empennage Fasteners / Attachment / Corrosion Pass Fail Vertical Stabilizer Deformation / Cracks / Signs of Wear / Corrosion Rudder and bellcrank tube interior Deformation / Cracks / Signs of Wear / Corrosion Stabilator and c' balance tube interior Deformation / Cracks / Signs of Wear / Corrosion Continued next page
18-17 Rev.10
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18-18
Rev.10
Fuselage Fasteners / Corrosion / Deformation Pass Fail Skins Deformation / Cracks / Signs of Wear / Corrosion Footprint Area of Left & Right Wing Signs of Wear Bulkheads & Stringers Deformation / Cracks / Signs of Wear / Corrosion Left & Right Static Ports Clean / Clear / Secure Left & Right Boarding Step Security / Seal
Landing Gear Fasteners / Corrosion / Refer to Matco manual Pass Fail Main Gear Legs / Brackets Security / Wear / Corrosion or Bubbled Paint Landing Gear Attach Hardware Torque Brake Hydraulic Lines Leaks / Security Wheel Bearings Lubrication / Free Play / Refer to Matco manual Brake Calipers Condition / Refer to Matco manual Brake Shoes Lining Limit / Refer to Matco manual Brake Disks Cracks / Deformation / Refer to Matco manual Wheels Alignment / Cracks / Refer to Matco manual Tires & Valve Stem Wear / Cracks / Air Pressure Nose Gear and Fork Travel / Security / Break-out Force / Internal* Cor.
Wings / Center Section Fasteners / Corrosion / Deformation Pass Fail Skins Deformation / Cracks / Signs of Wear / Corrosion Ribs & Attach Angles Deformation / Cracks / Signs of Wear / Corrosion Main, Fwd & Aft Spars Deformation / Cracks / Signs of Wear / Corrosion Flaperon and Torque Tubes Smooth Operation / Security / (Internal* Corrosion) Hinges Smooth Operation / Lubrication Stall Warning Secure / Connection / Condition Wing Retention Pins & Bushings Signs of Fatigue / Wear / Maximum I.D. 1.505 inch Center Section (Channel & Bulkheads) Deformation / Cracks / Signs of Wear / Corrosion * tube interior Continued next page
18-19 Rev.10
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18-20
Rev.10 Hinges & Rod Ends Free-play / Smooth Operation Component Skins Deformation / Cracks / Signs of Wear / Corrosion Control Cable Links & Push / Pull Tension / Wear / Fatigue Rods Control Stops Security / Deformation / Alignment Rear Spar Doubler Check for Gap
Paperwork Pass Fail Record Findings Aircraft Log Record Inspection Aircraft Log Record Maintenance Aircraft Log
Notes and explanation of discrepancies found:
End of inspection checklist
18-21
Rev.10
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18-22
Rev.10
ELECTRICAL SYSTEM SCHEMATICS
Refer to P. O. H. or http://www.vansaircraft.com/public/downloads.htm
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Rev.10
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18-24
Rev.10 3-VIEW
18-25
Rev.10
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18-26
Rev.10
Feedback Form Owner: Name Phone: Number Aircraft: Model Contact: Name Phone: Number Total Time Serial Number Inspector: Name Phone: Number Engine: Model Inspection: Date Storage: Inside/outside/etc Total Time Serial Number Location: City State Country
Affected Parts:
Problem Description:
18-27
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18-28 Rev.3
CHAPTER 19 - GLOSSARY 100-hr Comparable to an annual condition inspection, except that the Inspection interval of inspection is 100 hrs of operation instead of 12 calendar months. This inspection applies to LSA used for commercial operations such as flight instruction or rental, or both. A&P Airframe and power plant technician as defined in the U.S. by 14 technician CFR Part 65 or equivalent certification in other countries. Approved Some aircraft maintenance may be performed by an "Approved Owner Owner" found competent by Van's Aircraft. Approval will be for a specific task, person(s) and aircraft. F39 Refers to the FAA Advisory Circular ‘Acceptable Methods, Techniques, and Practices – Aircraft Inspection and Repair. Adverse Includes, but not limited to, conditions that could cause build up of conditions foreign matter or contamination or removal of lubrications, such as; extreme weather, and dirty, sandy or salty conditions, thorough plane washing, etc. Annual Detailed inspection performed once a year on an LSA in Condition accordance with instructions provided in the maintenance manual Inspection supplied with the aircraft and F39 Appendix D. The purpose of the inspection is to identify any wear, corrosion, or damage before it compromises the safe operation and airworthiness of the aircraft. Anti- AST. The anti-servo/trim tab has two functions. It provides Servo/Trim tab movement resistance (control force feed back), and also serves as a trim control surface. The trim function is controlled with the pitch- trim servo. As needed At first sign of wear or abnormal operation and/or following exposure to adverse conditions. CFR 14 Code of Federal Regulations Title 14 Aeronautics and Space also known as the FAR’s. Check To verify the correctness of, as by comparison to inspect or test the condition, performance, safety, etc., of Electronic EFIS. Refers to the Dynon D-180, Dynon Skyview or Garmin G3X. Flight The unit receives signals from multiple sensors on the airframe and Information engine, then provides valuable engine and flight information based System on the signals from the sensors. Emergency ELT. The electronic device unit that sends a distress signal when G Locating loads exceed a critical value, or when activated manually. Transmitter
19-1
Rev.3
Engine EMS. Refers to the Dynon D-180, Dynon Skyview or Garmin G3X. Management The portion of the EFIS unit that compiles and displays engine System information. Extreme Heavily contaminated air; dust, bugs, smoke, debris, ash, sand, etc. conditions or adverse climatic conditions Flaperon A control surface that combines the aileron and flap functions into one component with both functions Global GPS. A navigational system involving satellites and computers that Positioning can determine the latitude and longitude of a receiver on Earth. System Heavy Maintenance, inspection, repairs, or alteration that a manufacturer Maintenance has designated to require special training, equipment, or facilities. Only a qualified person may perform heavy maintenance. Kit Assembly KAI. Refers to the original kit assembly instructions that are Instructions provided by the manufacturer to complete the assembly of a kit plane. Line Any repair, maintenance, scheduled checks, servicing, inspections, Maintenance or alterations not considered heavy maintenance by the manufacturer with instructions provided in the manufacturer’s maintenance manual. LSA LSA-RI. U.S. FAA- certified repairman (light sport aircraft) with an Repairman inspection rating as defined by 14 CFR Part 65, authorized to Inspection perform the annual condition inspection on experimental light sport aircraft, or an equivalent rating issued by other civil aviation authorities. This requires a 16-hour course. LSA LSA-RM. U.S. FAA-certified light sport aircraft technician with a Repairman maintenance rating as defined by 14 CFR Part 65. This certificate is Maintenance authorization to perform line maintenance, inspections, and repairs on any LSA certified aircraft. The maintenance rating is category specific, I.E. Fixed wing, weight shift, lighter than air, etc. Maintenance Manual provided by an LSA manufacturer or supplier that specifies Manual(s) all maintenance, repairs, and alterations authorized by the manufacturer. Major Repair, Only a qualified person may perform major repair, alteration, or Alteration, or maintenance tasks that are not included in this maintenance Maintenance manual. Manufacturer Any entity engaged in the production of an LSA or component used on an LSA. Minor Repair, Generally applies to repair, alteration, or maintenance covered by Alteration, or instructions provided in the maintenance manual(s) supplied to the Maintenance consumer.
19-2 Rev.3
Overhaul Maintenance, inspection, repair, or alterations that are only to be accomplished by the original manufacturer or a facility approved by the original manufacturer of the product. Overhaul Facility specifically authorized by the aircraft or component Facility manufacturer to overhaul the product originally produced by that manufacturer. Pilot Operating POH. The handbook provided with the aircraft that introduces the Handbook systems and features that are included in the RV-12. Includes air and ground operating procedures and defines performance and weight and balance information. Preventative Simple or minor preservation operations and the replacement of maintenance small standard parts not involving complex assembly operations Special Light S-LSA. Applies to the aircraft covered in this manual, provided it Sport Aircraft remains consistent with the manufacturers design specifications. Manufacturer design specifications are in accordance with ASTM standards; F2245 for airplanes. Repair Facility Facility specifically authorized by the aircraft or component or Repair manufacturer to repair the product originally produced by that Station manufacturer. Sport Pilot SPC. A person who holds a current Sport Pilot Certificate. A Certified certified sport pilot may perform preventative maintenance and approve for flight a private use S-LSA aircraft that they own or operate. Stabilator An aircraft control surface that combines the horizontal stabilizer and elevator into one fully movable component.
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19-4
Rev. 4
CHAPTER 20 - INDEX
A
AOA (see Angle-Of-Attack) Abbreviations ...... 1-6 Air filter ...... 12-3 Oil ...... 1-11 Inspection ...... 3-9 Installation ...... 12-7 Removal ...... 12-7 Angle-Of-Attack Sys. Press. Check...... 3-12, 5-13 Anti-servo / trim tab ...... 5-6, 5-7 Inspection ...... 3-15 Lubrication ...... 5-26 Avionics ...... 9-1
B
Battery ...... 8-5 Charging ...... 8-14 Installation ...... 8-5 Removal ...... 8-5 Terminals ...... 8-14 Bellcrank Bearing ...... 6-8 Stops ...... 3-6 Brake pedal Lubrication ...... 7-4 Brake Shoe Lining Inspection ...... See Matco Manual Replacement ...... 7-6 Brake System ...... 7-1 Drain ...... 7-5 Flush ...... 7-5 Substitute Parts...... 17-2
C
Canopy ...... 5-3 Cleaning ...... 1-11 Installation ...... 5-14 Inspection ...... 3-5 Latch Block ...... 5-3, 5-23 Removal ...... 5-14 Capacities...... 1-13 Carburetor Syncronization ...... 12-7 Center Section Inspection ...... 3-13 Cherry Rivet (see Rivet, Blind, ...) Cockpit Inspection ...... 3-5
20-1
Rev. 4
Control cable Replacement ...... 6-6 Control Stops ...... 3-6 Control system ...... 6-1 Rod-End Lubrication ...... 6-9 Coolant ...... See Engine Cowl Hinge ...... 12-2, 12-16 Cowling Installation ...... 12-5 Removal ...... 12-4 Cylinder Removal ...... 12-18
D
Decorative paint ...... 15-5 Dynon ...... 9-2, 9-3, 9-4, 18-3
E
Electrical System ...... 8-1 Schematic ...... see POH Terminal Tab ...... 8-10 Emergency Locator Transmitter Inspection ...... 3-7 Empennage ...... 5-6 Inspection ...... 3-13 Engine ...... 1-12, 12-3 Firing Order ...... 12-3 Inspection ...... See Rotax Manual Lubrication Coolant ...... 12-6 Oil ...... 1-13, 12-6 Operating limits ...... See Rotax Manual Replacement ...... 12-18 Specifications ...... See Rotax Manual Equipment List ...... 1-21 Exhaust System ...... 14-1 Installation ...... 14-3 Lubrication ...... 14-4 Removal ...... 14-3
F
Feedback...... See Safety Firewall Forward ...... 12-1 Inspection ...... 3-8 Flaperon ...... 5-4 Lubrication ...... 5-25 Fuel System ...... 13-1 Draining ...... 13-4 Fuel Tank Installation ...... 13-6 Removal ...... 13-5 Fuselage...... 5-2 Inspection ...... 3-10
20-2
Rev. 4
Lift and Support...... 1-16 Terminal Tab ...... 8-14 Inspection ...... 3-9 Fuselage Pins ...... 5-3 Fuses ...... 8-6
G
Garmin ...... 9-2, 9-4 Gascolator Cleaning ...... 13-7 Installation ...... 13-7 Inspection ...... 3-9 Removal ...... 13-7
H
Harness, Shoulder ...... 5-3 Inspection ...... 3-5 Replacement ...... 5-22 Heat ...... See Utilities Hinge Cowl ...... 12-16 Hinge Anti-Servo Tab ...... 5-25 Flaperon ...... 5-17 Rudder ...... 5-18 Stabilator ...... 5-19
I
Idle Setting ...... 12-12 Inner tube Main ...... 5-16 Nose ...... 5-17 Inspection ...... 3-1 Checklist ...... 18-7
L
Landing Gear ...... 5-8 Inspection ...... 3-11 Lights ...... 8-1 Lubricant...... 1-11 Lubrication ...... 1-13
M
Main Landing Gear Bearings ...... 5-27 Inspection ...... 3-11 Installation ...... 5-21 Removal ...... 5-21 Main Wheel and Tire Inspection ...... 3-11
20-3 Rev. 4
Installation ...... 5-15 Removal ...... 5-15 Main Wheel Assembly ...... 5-9 Master cylinder Installation ...... 7-4 Removal ...... 7-3
N
Nose Gear Leg Fairing ...... 5-10 Nose Landing Gear ...... 5-8 Inspection ...... 3-11 Lubrication ...... 5-26 Removal ...... 5-21 Nose Wheel and Tire Bearings ...... 5-26 Installation ...... 5-16 Removal ...... 5-16 Nose Wheel Assembly ...... 5-9
O
Oil ...... See Engine
P
Paint ...... See Painting and coating Painting and Coating ...... 15-1 Panel Circuit Board ...... 8-9 Piston Removal ...... 12-18 Pitch-Trim Servo Replacement ...... 8-7 Pitot & Static ...... 9-3 Powder coat Repair ...... 15-3 Primer ...... 15-4 Propeller ...... 11-1 Inspection ...... 3-7, 11-3 Push/pull cable ...... 10-2 Inspection ...... 3-6, 3-9 Lubrication ...... 10-5
R
Radio Inspection ...... 3-7 Rear Spar Doubler Check ...... 3-13 Doubler Replacement ...... 5-23 Lubrication ...... 5-23 Rivet Blind, Cherry Max Alternative ...... 4-2 Inspection ...... 3-10 Rod end Lubrication ...... 6-9
20-4
Rev. 4
Replacement ...... 6-7
Rudder Pedals Installation ...... 6-9 Removal ...... 6-8 Rudder ...... 5-7 Inspection ...... 3-14 Removal ...... 5-18 RV-12 3-View ...... 18-25 Summary ...... 1-1
S
Safety ...... 1-4 Feedback ...... 17-1 Feedback Form ...... 18-27 Sensenich...... See Propeller Service Schedule ...... 2-1 Table ...... 18-3 Snap bushing ...... 8-13 Software ...... 9-6 Spark Plug ...... 12-3 Replacement ...... 12-5 Stabilator ...... 5-7 Control cable pulley ...... 6-3 Inspection ...... 3-15 Stub Spar Lubrication ...... 5-23 Supplement ...... 18-1 Substitute Parts ...... 17-3
T
Throttle Cable Lead Hookup ...... 12-10 Throttle Spring Replacement ...... 12-15 Tire Assembly Balancing ...... 5-29 Pressure ...... 1-14 Torque ...... 1-15 Troubleshooting ...... 16-1
U
Units ...... 1-7 Utilities ...... 10-1 Heat ...... 10-2 Ventilation ...... 10-3 Vent door ...... 10-5
V
Vacuum Gauge Hookup ...... 12-11 Ventilation...... See Utilities Vertical Stabilizer ...... 5-7 Inspection ...... 3-13
20-5
Rev. 4
W
Weight and Balance ...... 1-18 Wheel Bearings Main ...... 5-26 Nose ...... 5-25 Wing Attach Location Lubrication ...... 5-25 Fuselage Pins ...... 5-25 Stub Spar and Rear Spar ...... 5-25
20-6